Customer case

Hardox® 500 Tuf wear steel lightens every load for dump truck body manufacturer IWS

September 14, 2020 6 min read

Case details

Country United States
Company Industrial Welding Supply
Industry Trailers and body builders
Brand program Hardox® In My Body

Industrial Welding Supply is a leading Colorado truck and trailer supplier featuring dump truck bodies and trucks built-to-order for a growing US market. As an early adopter of SSAB’s new wear-resistant steel grade Hardox® 500 Tuf, IWS will transition all its Hardox® In My Body certified products to the new material, giving customers lighter vehicles with higher payloads, safer operation and an even longer service life.

Hardox® 500 Tuf is an abrasion-resistant (AR) steel and a perfect fit for high-performance dump truck bodies. Hardox® 500 Tuf is the first 500 Brinell (HBW) wear plate with properties on a par with structural steel. It delivers high strength, extreme hardness and guaranteed toughness in a single wear plate. While improving dent protection, the material also offers a 70-100% longer service life compared to conventional 400 HBW AR steel.

“As soon as my customers hear the benefits of Hardox® 500 Tuf, they don’t want it as an option, they want it standard. The weight savings alone grab their attention, and then there’s the longer service life,” says JD Stone, IWS Vice President and General Manager. “These trucks are workhorses and must be able to take a beating over time, and now that we’ve transitioned fully to the new material, we only deliver the upgraded version.”

An elliptical-style dump truck body made in Hardox 500 Tuf that is ready for dumping.
Industrial Welding Supply’s elliptical style dump truck body in Hardox® 500 Tuf has really caught customers’ attention due to longer service life and reduced weight.

Less truly is more in dump truck bodies

By using Hardox® 500 Tuf wear plate in a thinner dimension, the new generation of Colt-brand dump truck bodies delivers 14% less tare weight with one and a half times the service life as the previous generation. This allows for an increase of payload capacity by 14% at the same total weight.

“The first four of my dump bodies made of Hardox® 500 Tuf went to a long-time customer of ours in Denver, CO. Operating in the construction sector, every trip counts, and now with the added payload capacity, drivers can haul more in fewer trips. When you think about it, that means they also consume less fuel,” Stone explains.

Truck fleet owners are keenly aware of rising fuel costs and beginning to scrutinize environmental concerns. They also focus heavily on safety. With less material in each truck, an upgrade to Hardox® 500 Tuf positively impacts all of those factors.

“Many of my customers are dealers of the major brands including, Kenworth, Peterbuilt, Mack, Freightliner and International. These companies demand the highest quality, and every component of our trucks is selected to be the best of its kind – even down to using flexible automotive paints,” Stone explains. “Hardox® 500 Tuf is the next generation of premium wear steel, and we’re excited to fully adopt it and introduce the first box of its kind to the US market.”

The general manager of Industrial Welding Supply standing in front of a Colt-branded and Hardox® in My Body-certified custom truck body.
JD Stone, VP and General Manager at Industrial Welding Supply, demands the highest quality components for his custom line of Colt- branded and Hardox® in My Body certified dump trucks.

Making friends in the workshop

When it comes to comparing weldability and bendability of Hardox® 500 Tuf with Hardox® 450, the properties are nearly identical, except that Hardox® 500 Tuf performs equally well at thinner dimensions. According to Phil Raffaeli, IWS Production Manager/Sales, it can be fabricated with the same equipment used for Hardox® 450 . For the six master welders, who have a combined 100 years’ experience, and the World War II era rolling bending press at IWS, Hardox® 500 Tuf was easy to incorporate into production.

“We use the same rolling equipment for Hardox® 500 Tuf as we did for Hardox® 450. The chimes rolled for our elliptical box designs can be slightly shorter and overall thinner going from 0.188” (4.8 mm) to 0.157” (4 mm). Our guys were able to adjust quickly and transitioned smoothly between the two grades,” Raffaeli says.

Truck with a black dump body being filled with abrasive material.

Hard and tough in the Rocky Mountain cold

Even though Colt trucks find their way outside of Colorado, many of the 200 bodies produced annually by dump body manufacturer IWS are guaranteed to face cold conditions during their service lives. To tackle bitter conditions, Hardox® 500 Tuf has a guaranteed impact energy of 27 J at -20°C (20 ft-lb at 4°F) and, for 20 mm plate, a typical value of 45 J at -40°C (33 ft-lb at 40°F). It also features an unusually narrow hardness window of 475-505 HBW.

According to SSAB’s wear calculation app, WearCalc, the estimated relative service life for Hardox® 500 Tuf is 27% longer than for Hardox® 450 based on sliding wear with sand. For more details, refer to the graphic showing the calculation results, which also can be generated from within the WearCalc app . Upgrading material selections also boosts the bottom line. Using SSAB’s EcoUpgraded app , IWS calculated an annual profit increase of $2,450 because of switching to Hardox® 500 Tuf.

Apps' reports

From blacksmith to black box

In the 1920’s, blacksmiths fashioned and hammered out parts for the railcars that rumbled along the back side of IWS’ first building on Front Street. Today, Stone, who is completely committed to quality, not only carries on the tradition of turning out only the best, but continues to evolve with innovative upgrades to serve customers in agriculture, oil and gas, trucking, trailers and tanks.

This elliptical style dump body featuring Hardox® 500 Tuf allows end users in North America to experience Hardox® wear plate’s innovative evolution in advanced wear steels.

“Over the past few years, I’ve watched the trucking industry’s demand rapidly grow for an even harder, tougher material,” says Tobias Appelkvist, Regional Sales Manager, SSAB Special Steels. “We fully support efforts by our Hardox® In My Body certified member , IWS, as they work to meet their customers’ needs.”

Stone and Raffaeli are impressed not just by the quality of the new steel grade, but also by SSAB’s steady commitment to support and service.

“I fully appreciate the expertise of SSAB’s technical services team to partner in testing new ideas and applications,” Stone explains. “It’s one of the many reasons partnering with them puts my business ahead of the curve. We also count on the market-leading quality of their special steel products knowing they will perform as promised. I look forward to our next test of new materials as we broaden our offerings.”

Three smiling men in front of the first Colt-branded dump truck made of Hardox® 500 Tuf, from Industrial Welding Supply.
JD Stone, VP and General Manager at Industrial Welding Supply is joined by Tobias Appelkvist, Regional Sales Manager SSAB and Phil Raffaeli, IWS Production Manager to roll out the first Colt-branded dump truck body made of Hardox® 500 Tuf.

Watch how IWS lightens every loads

Get an upgrading consultation

Find out what upgrading to Hardox® 500 Tuf can do for your equipment and your operations. We’ll be happy to meet you and find out about your specific wear environment and needs to find the best and most cost-effective solution for your business.

End users around the world use Hardox® 500 Tuf in their tippers

Thompsons UK gets thinner wear plate and longer service life with Hardox® 500 Tuf

“The increased abrasion resistance of Hardox® 500 Tuf allows us to use a thinner plate and keep the same excellent service life. Not only that, thinner steel reduces the body weight, which allows for higher payload.”

The lifetime of Zetterberg’s dumpers has increased by 40 percent

In addition to the increased service life, Hardox® 500 Tuf has allowed Zetterberg to reduce the tare weight by 20% or 650 kg (1,433 lbs.).

”Since we upgraded the steel to Hardox® 500 Tuf wear-resistant steel, we have increased the useful life of our dumpers by at least 40 percent.”

Find out how upgrading pays off

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