Over nearly a decade of use, the tractor-trailer gap enclosure device called TruckWings has helped fleets soar to new heights of efficiency, with up to 6% average annual fuel savings. The aerodynamic system spreads out (from the back of the cab) at highway speeds to keep wind away from the front of the trailer, reducing drag and the amount of work an engine needs to do to chug along.
ConMet liked the concept—and results—so much that they acquired the startup that makes the device, TruckLabs, in 2023, keeping on founder Daniel Burrows as general manager and VP of the brand. In October, ConMet announced the device hit 1 billion miles of use. Because of TruckWings’ reliability over that time, and being more integrated into ConMet’s considerable supplier network, the company is now extending the warranty from one year and 100,000 miles to five years/500,000 miles. Burrows previously said TruckWings systems are designed to last 1 million miles.
According to Andrew Kelly, VP and product manager of TruckWings, the decision was based on those 1 billion miles of operations and various improvements to the aero device. More importantly, the third generation of TruckWings simply doesn’t need much warranty work.
“Our most recent warranty rate is just a few tenths of a percent in terms of revenue, which demonstrates the product’s reliability and durability,” Kelly told Fleet Maintenance.
That 5-year/500,000-mile number also aligns with the standard for OEM-installed aero components on the cab, signaling the system “is ready to be integrated as a factory-fit option for customers,” Kelly added.
As an aftermarket add-on, installation times are about two hours. More often, though, fleets concerned with fuel costs—as well as extending range for BEVs—are receiving their tractors with the device already attached.
“It’s a solution that is already considered standard equipment by some of the largest fleets in the country, with strong support from OEMs and installation centers,” Kelly noted.
What does the warranty cover?
The warranty will apply to any issues arising from material or workmanship defects.
“If a covered component—like the actuator, airflow control box, or panels—fails under normal operating conditions during the warranty period, it’s on us to make it right,” Kelly said.
The work can be done by dealers or the fleet, as long as they follow ConMet's procedures. The user needs to submit the claim to the warranty department for approval and obtain the authorization number for the return materials.
For approved claims, ConMet covers repair/replacement costs. Fleets that do the work themselves are reimbursed for labor based on ConMet standard repair time rates.
The warranty does not cover damage due to neglect, accidents, or improper use.
TruckWings comes with a telematics feature that allows the company’s customer success team to monitor the equipment and proactively alert fleets to possible issues. This also includes preventive maintenance reminders about upcoming planned maintenance.
Built for winter
A skeptic may wonder how these TruckWings fare in winter weather, considering most winged creatures fly south to avoid the ice and cold. And birds don’t have to contend with corrosive road salts and chemicals like these metal ones do. TruckWings are made from corrosion-resistant 5052-series aluminum, composite panels, and engineered plastics—as well as steel fasteners coated with zinc aluminum plating—all of which help the system stand up to “prolonged exposure to road salt, moisture, and temperature fluctuations,” Kelly said.
The ConMet brand also conducts lab and field tests in the Northern U.S. and Canada, and TruckWings still maintain their appearance and structural integrity after several winters.
On-road testing also indicates the components stand up to severe real-time weather and freezing temperatures as low as -40 degrees F.
“We did extensive testing, freezing our hinges and calculating the necessary force required to break free for deployment or retraction,” Kelly said. “The force provided by the three pneumatic actuators designed to deploy against a 55-mph crosswind directly hitting the side panel is more than adequate to drive the panels open in any freezing environment.”
