W W W . I S T R A I L . C O M TECHNOLOGY Metallization – an effective method for protecting truck body components INDUSTRY How modern body constructions improve transport efficiency and safety FEATURED PRODUCT Flatbed trailer with turntable – ps-150 model 03/2025 (03)
02 Publisher: ISTRAIL sp. z o.o. ul. PTTK 56 87-400 Golub-Dobrzyń kontakt@istrail.pl Edition and typesetting: Feniks Media Group ul. Balicka 136, 30-149 Kraków Authors: Ewa Koczwara, Piotr Kołaczek, Agnieszka Szmuc, Radosław Urban The news magazine uses images from the Getty Images library and from the archives of ISTRAIL sp. z o.o. TECHNOLOGY 04 Metallization – an effective method for protecting truck body components INDUSTRY 06 How modern body constructions improve transport efficiency and safety PRODUCTS 10 Tipper bodies with aluminum cargo boxes 06 04 14 Table of contents 12 Centrally-axled container trailer with tk-138 tipping system 13 Container trailer with turntable and tipping system – pkw-184 / pkw-186 FEATURED PRODUCT 14 Flatbed trailer with turntable – ps-150 model
03 Dear Readers, We are pleased to present to you the latest edition of ISTRAIL News, in which we focus on solutions that enhance efficiency in heavy- -duty transport. This issue offers a cohesive overview of a modern approach to the design of trailers, semi-trailers, and truck bodies—an approach where technology matters, but understanding the user’s needs and broad customization capabilities are of equal, if not greater, importance. We begin with a topic relevant to every vehicle owner: the durability of truck bodies, trailers, and semi-trailers, and how to effectively combat corrosion. The article dedicated to metallization technology demonstrates how vehicles can be efficiently protected against rust, significantly extending their service life and utility value. We highlight solutions applied at ISTRAIL’s facility in Golub-Dobrzyń—our company was the first to apply metallization to exposed structural elements of truck bodies, a distinctive feature of ISTRAIL trailers, semi- -trailers, and body systems. This edition also explores modern body systems, their customization options, functionality, and their impact on transport safety. We specifically address multi-purpose bodies, such as ISTRAIL’s combi body, which combines tipping and fifth-wheel functions. More details can be found in the article „How Modern Bodies Support Efficiency and Transport Safety.” We have also prepared presentations of specific products: detailed descriptions of aluminum bodies characterized by their lightweight construction, corrosion resistance, and broad application potential. We introduce long-trailer type trailers designed for transporting oversized loads. These products offer extensive configuration options, including number of axles, sidewall type, brake system, and suspension design. This section also features container trailers that prove highly effective in sectors such as construction and municipal services. As a manufacturer, our goal is not only to deliver top-quality equipment, but also to share knowledge, inspire innovation, and support the growth of our clients. Each edition of ISTRAIL News is created with our customers in mind, addressing real-world challenges faced by transport companies across Europe. We invite you to read on! Dariusz Gębarowski Chief Executive Officer ISTRAIL sp. z o.o. The article dedicated to metallization technology demonstrates how vehicles can be efficiently protected against rust, significantly extending their service life and utility value. We highlight solutions applied at ISTRAIL’s facility in Golub-Dobrzyń — our company was the first to apply metallization to exposed structural elements of truck bodies, a distinctive feature of ISTRAIL trailers, semi- -trailers, and body systems.
Purchasing a heavy-duty vehicle is a long-term investment that should offer a reasonable return over time. In the case of trailers and body systems, each additional year of use significantly increases cost-efficiency. This is why both manufacturers and transport company owners pay close attention to vehicle lifespan and the additional costs associated with inspections, repairs, and refurbishments. When estimating the total cost of ownership, it’s crucial to consider every detail. The best approach is to verify the manufacturer’s claims—examining how their vehicles and superstructures are built, and more importantly, how they are protected against damage, wear, and above all, corrosion. Factors contributing to corrosion Corrosion can arise from a variety of causes and develop in different ways. It typically begins with mechanical damage to steel components, which increases their exposure to the atmosphere. The process accelerates when aggressive chemical compounds are present, or when the environment becomes highly acidic or alkaline. Electrochemical reactions can also be triggered by contact with dissimilar materials. Heavy-duty vehicles – especially those used in off-road or construction environments – are exposed to a wide range of corrosive factors, including chemically active construction materials and salt-laden slush from winter roads. High temperatures (e.g., when transporting asphalt or bitumen), humidity, mechanical impacts, and abrasion during loading/unloading further exacerbate the issue. Under such harsh conditions, even the most robust factory coatings may fail to prevent corrosion within the first few years of operation. Traditional protection methods Traditional corrosion protection consists of multilayer paint systems – starting with a strong anti-corrosive primer, followed by intermediate coatings, and a hardened, impact-resistant topcoat. An additional level of protection can be achieved using galvanized components. However, maintaining these systems in good condition is complex and costly. Structural elements must be regularly inspected to detect early signs of damage: cracks in the coating, initial corrosion, or delamination. Any identified issues require immediate repair. The vehicle must be taken out of service, cleaned, and prepared for workshop treatment, which may involve the disassembly of certain components – a time-consuming and expensive process. If corrosion is left unaddressed, it may eventually lead to the vehicle’s premature withdrawal from service, even if the overall mechanical condition remains acceptable. Metallization An effective method for protecting truck body components 04 TECHNOLOGY
Metallization – proven corrosion protection One of the most effective methods of protecting steel or other metal components from corrosion is metallization, which involves applying a metallic coating that adheres tightly to the substrate and provides excellent resistance to rust. Several methods and coating materials are used in practice, including: • APS – Atmospheric Plasma Spraying: coatings of chromium oxide, aluminum oxide, zirconium dioxide, tungsten carbide, • HVOF – High-Velocity Oxygen Fuel Spraying: tungsten carbide and chromium carbide coatings; known for high-speed application and oxide-free layers, • AWS – Arc Welding Spraying: zinc and aluminum coatings, carbon and alloy steels, bronze, brass, etc., • FWS/FPS – Flame and Powder Wire Spraying: zinc and aluminum, molybdenum, carbon and alloy steels, bronze, brass, and copper. Metallization at ISTRAIL At ISTRAIL’s production plant in Golub- -Dobrzyń, metallization is used to protect structural elements of truck bodies, trailers, and semi-trailers. The effectiveness of this method has been confirmed by long-term field performance, especially under harsh environmental conditions. Metallized surfaces can be left uncoated or finished with traditional paint systems. ISTRAIL’s extensive experience in truck body metallization shows that this process significantly increases component durability – and, by extension, the operational life of the vehicle itself. Metallization of structural components is a standard feature in ISTRAIL products and is included at no extra cost. Additionally, all metallized components are covered by a 3-year warranty, demonstrating ISTRAIL’s commitment to quality and longevity. 05 TECHNOLOGY Have you known? In winter, water in lakes near Norwegian roads can be up to ten times saltier than seawater, creating extreme corrosion conditions. That’s why ISTRAIL is the only manufacturer to offer metallization of dump truck and trailer body components as standard—backed by a 3-year warranty on metallized surfaces. www.istrail.com Every truck operator knows how quickly rust becomes a cosmetic and financial problem. ISTRAIL has addressed this with metallization, offering long-term, rust- -free durability. ISTRAIL is the first company in Norway to implement this solution as standard, ensuring peace of mind for our customers. ISTRAIL – as the first company in Norway – offers this solution and provides a three-year warranty on metallized parts. The anticorrosion treatment extends the life of parts and increases their value in use. The metallization is a standard feature of ISTRAIL products and is available at no extra charge. www.istrail.com
06 INDUSTRY How modern body constructions improve transport efficiency and safety A superstructure is an integral part of a commercial vehicle. The vehicle’s performance determines where it can operate, the payload it can carry and the level of comfort and safety for the driver and crew. However, from an operational standpoint, it is the superstructure that plays the deciding role.
The superstructure defines whether the chassis serves as a universal platform or is built for a specific, targeted function. The quality of the superstructure also significantly affects operational costs. Assuming a vehicle operates under standard manufacturer‑specified conditions, the superstructure is the component most prone to damage and failure. It is vulnerable during loading and unloading, and its robustness determines the safety of transported goods or vehicles. The speed at which worn components can be replaced directly impacts vehicle downtime and associated costs. Customization is key To optimally meet user requirements, customization is essential. Full personalization — tailoring the superstructure to specific needs — can only be achieved through bespoke design and manufacture. Of course, this is bounded by road‑traffic regulations and the manufacturer’s production capabilities. Customization and personalization distinguish ISTRAIL in the trailer and superstructure market. A client‑centric approach defines every stage of development: requirement analysis, engineering documentation, production, operation, and service. Color and visual identity Custom‑built superstructures can be finished in any color, either solid or with client‑designed graphics. This supports corporate visual standards, strengthens brand recognition, and enhances marketing impact. It also enables placement of identification markings and safety/hazard signage to maintain safe clearing distances or highlight load‑related risks. Advanced painting techniques can be applied: multilayer coatings, hardened or matte finishes, or engineered reflectivity for light‑management. Tailored geometry In certain applications, mass and footprint aside, geometry matters. For example, military vehicles are built to NATO specifications, and other special‑purpose vehicles (e.g., mining, forestry) may 07 INDUSTRY
08 require exact dimensions to negotiate narrow paths, ferry decks, or ramps. Smartly designed movable superstructure elements — optionally regulated hydraulically — facilitate operations on steep inclines without damaging bumpers or chassis. Low‑loader trailers Low‑loader trailers designed for heavy machinery can be engineered with features to simplify routine operations. Customized anchor point layouts, storage boxes for accessories (e.g. chains), and ramp systems (including hydraulically powered) can streamline securement and deployment. These adjustments optimize vehicle and driver utilization and reduce operating costs over time. Trailers may include standard, universal, or adjustable load‑securing systems, enabling multi‑client use. Load safety Incorrect or shifting loads are among the most hazardous ISTRAIL vehicles can be equipped with necessary securing systems: removable stanchions, sidewalls with variable locking mechanisms, and additional loadretaining bars. INDUSTRY
road transport issues. At best, they impair vehicle handling, increase tire wear, and damage components; at worst, they cause accidents. Risk mitigation can be achieved in two ways: Sensor systems warn against overload, axle or wheel imbalance, with active alerts during loading and transit — allowing immediate corrective actions. Ergonomic securing systems enable drivers to adjust load attachments easily without delays or heavy effort. ISTRAIL vehicles can be equipped with necessary securing systems: removable stanchions, sidewalls with variable locking mechanisms, and additional load-retaining bars. Tipper superstructures Tippers are a class of specialist superstructures—available as truck bodies, trailers, or semi‑trailers. Although they appear similar, their construction depends on the specific task. For high‑abrasion use (e.g., aggregates, rubble, scrap), ISTRAIL uses wear‑resistant steels like Hardox, which resist deformation and abrasion, prolonging service life. For lighter bulk materials (e.g., powders, grains), aluminum tippers reduce tare weight, improving fuel efficiency, tyre life, and longevity of suspension and brake systems. ISTRAIL offers a variety of hydraulic cylinders differing in stroke, load capacity, and operating parameters. Quality components from reputable suppliers ensure reliability and spare‑part availability. Tipper configurations are highly flexible: lift direction, tailgate type, and hydraulic tailgate operation (including opening prior to dump) are all possible. Interchangeable superstructures For customers with limited truck fleets but diverse applications, ISTRAIL offers interchangeable bodies. A single chassis can carry a box, tipper, or other superstructure type. Changeover is tool‑free: deploy support jacks, disconnect hydraulics/ pneumatics/electrics, drive the chassis away, and attach a new body. Ideal for municipal services, agriculture, or technical operations. 09 Combi superstructure – one chassis, two functions The combi superstructure merges the functions of a tipper and a tractor unit. It features a quick‑release mechanism for the tipper body and a tipping cylinder, enabling rapid conversion from tipper mode to a tractor unit configuration for semi‑trailers. This setup is ideal for operators seeking cost savings and operational flexibility in response to changing market demands. INDUSTRY
10 An aluminium tipper body is ideal for transporting lightweight, high-volume materials. Thanks to the use of aluminium—much lighter than steel—the vehicle achieves increased payload capacity while maintaining a low kerb weight. aluminum cargo boxes Tipper bodies with Aluminium body construction The tipping box is made of aluminium, which ensures low weight and high corrosion resistance. This enhances payload potential and structural durability. The solution is ideal for transporting low-density bulk materials and other lightweight cargo. Rear tailgate options The upper tailgate is an aluminium swing-type panel that facilitates loading and unloading. The lower tailgate is 400 mm high, hydraulically controlled and opens automatically, allowing precise material discharge – particularly useful for granular or loose cargo. Front-mounted hydraulic cylinder A robust, high-performance hydraulic cylinder is used for body lifting, ensuring smooth and safe tipping. The front-mounted configuration provides optimal force distribution, increasing the vehicle’s stability during unloading operations. Customizable hydraulic tank and pump parameters The hydraulic oil tank capacity and pump specifications are configured according to the client’s specific operational requirements.. VBG coupling system Each tipper body is equipped with a VBG coupling, ensuring safe and reliable connection with various trailer types. This enhances the operational flexibility and versatility of ISTRAIL vehicles. Key features of aluminium tipper superstructures PRODUCTS
11 Available chassis accessories • additional wear plate (HB 450 steel, 3 mm thick) bolted to the floor for extra protection • plastic fenders (Parlok-type) or fenders made of aluminium / stainless steel • open chain boxes and lockable toolboxes mounted on the chassis frame • pneumatically controlled coupling (Luftservo) • chain hooks What else to know about aluminium? • Using aluminium in the Audi A8 body reduced the vehicle’s weight by 239 kg. • Lighter electric vehicles using aluminium can travel further on a single charge. • Aluminium is widely used in shipbuilding—ferries, yachts, and naval vessels—due to its low weight, corrosion resistance, and machinability. • Trains like the French TGV use aluminium in their structures to enhance speed and capacity. • Aluminium is fully recyclable and retains its properties after recycling. • Recycling aluminium uses only 5% of the energy required for primary production, reducing energy consumption and CO2 emissions. Advantages of aluminium tipper superstructures Aluminium bodies reduce the vehicle’s overall mass, increasing payload efficiency and lowering fuel consumption. Lightweight design The inherent corrosion resistance of aluminium extends the service life of the superstructure, especially under harsh environmental conditions. High corrosion resistance Aluminium bodies offer a modern, professional appearance – contributing to a strong brand image for transport operators. Aesthetic appeal Aluminium is 100% recyclable and supports sustainability objectives and eco-friendly transport policies.. Environmental sustainability Aluminium superstructures are suitable for transporting high- -volume, lightweight goods across a wide range of industries. Versatility PRODUCTS
12 The TK-138 is a three-axle central axle trailer designed for the transportation of all types of roll-off containers used for carrying grain, sand, gravel, rubble, waste, scrap, and similar materials. tk-138 tipping system Centrally-axled container trailer with The trailer features an integrated subframe with a hydraulic tipping cylinder, enabling container unloading in the same manner as a standard tipper trailer. The trailer’s gross vehicle weight rating (GVWR) is 27 tonnes. It is designed for use with three-and four-axle trucks equipped with hooklift systems. Standard equipment • Telescopic drawbar with pneumatic locking system • Air suspension system • SAF or BPW axles • Single wheels, size 385/65 R22.5, available with steel or aluminium rims • Wabco braking system with disc brakes • PVC mudguards • Hydraulic system with NUMMI PRO under- -body tipping cylinder, optimized for reduced container tipping cycle time Popular optional equipment • Aluminium rims • Additional toolboxes • Fixed drawbar integrated into the chassis frame • Pneumatic strap/chain tensioner for container securing • Container support beams with locks for transporting ISO containers A specialized variant of this model is available for the transport of dangerous goods in accordance with ADR regulations. PRODUCTS
13 The PKW-184 / PKW-186 container trailer is available in two-, three-, and four-axle configurations. It is designed for transporting all types of roll-off containers used for materials such as grain, sand, gravel, construction debris, waste, and scrap metal. pkw-184 / pkw-186 Container trailer with turntable The trailer is equipped with an additional subframe and a hydraulic tipping cylinder, allowing the container to be unloaded in the same manner as a conventional tipper trailer. • A specialized variant of this trailer is available for the transport of dangerous goods in accordance with ADR regulations. • Other popular models for transporting roll-off containers without a tipping function include: PK-180, PK-181, PK-182, and PK-183. • The applications, standard and optional equipment, as well as available specialist variants of the PK-180 to PK-183 series are identical to those of the PKW-184 / PKW-186. Standard equipment • Telescopic drawbar with adjustable length • Air suspension system • SAF or BPW axles • Twin wheels, size 265/70 R19.5, with steel or aluminium rims • Wabco braking system with disc brakes • PVC mudguards • Hydraulic system with NUMMI PRO underbody tipping cylinder, optimized for faster tipping cycle times Popular optional equipment • Telescopic drawbar with pneumatic locking system • Aluminium rims • Additional toolboxes • Fixed drawbar integrated into the chassis frame • Pneumatic strap/chain tensioner for container securing • Container support beams with locks for ISO container compatibility • Single wheels, size 445/45 R19.5, as an alternative to standard twin wheels Gross vehicle weight ratings (GVWR) two-axle version 20 tonnes three-axle version 30-38 tonnes four-axle version 42 tonnes It is intended for use with three- and four-axle trucks equipped with hooklift systems. PRODUCTS and tipping system
The PS-150 turntable flatbed trailer is available in a variety of configurations: two-, three-, four-, and five-axle versions, depending on specific transport requirements. It is primarily used for transporting palletized goods, long or oversized items, ISO containers, and small machinery. 14 Flatbed trailer with turntable ps-150 model Equipment of the longtrailer-type trailer / semi-trailer plywood floor with numerous load securing points air suspension SAF or BPW axles detachable front wall, 1600 mm in height single or twin wheels in various sizes, with steel or aluminium rims opening aluminium sideboards Wabco braking system with disc brakes telescopic drawbar with adjustable length three toolboxes made of aluminium or stainless steel FEATURED PRODUCT
15 Popular optional equipment • aluminium rims • additional toolboxes • telescopic drawbar with pneumatic locking mechanism Typical applications of longtrailer-type trailers/semi-trailers 1. Transport of structural elements Ideal for long beams, pipes, steel profiles or other construction components. 2. Transport of small construction machinery Suitable for carrying small construction equipment and tools. 3. Transport of containers and prefabricated elements Can carry ISO containers or prefabricated construction parts. 4. Transport of industrial equipment Used for transporting industrial devices such as generators, industrial furnaces, or production line components. Longtrailer-type trailers are widely used across various industries for transporting cargo that, due to its dimensions, cannot be carried by conventional means. Their advanced design and adaptability make them an indispensable tool in the transport and logistics sector. FEATURED PRODUCT Gross vehicle weight ratings (GVWR) two-axle version 20 tonnes three-axle version 30 tonnes four-axle version 38 tonnes five-axle version 42 tonnes
www.istrail.pl www.facebook.com/Istrail.Polska www.linkedin.com/company/istrail Nordre Kullerød 17 3241 Sandefjord tel. +47 35 94 87 50 istrail@istrail.com ISTRAIL AS
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