Ready to comply with the EN 12642XL regulation ?

Everyone has already heard about, or even seen, horrible accidents where trailers are involved who lose their loading on the roadway. In order to reduce the number of these dramas, a new regulation was created to specify the strength of the trailers’ superstructure.

This new EN 12642XL regulation has forced every trailer builder and parts manufacturer to develop new and better solutions to create an even stronger and safer trailer. Probably your trailers are already reinforced with all kinds of webbings, wires or even steel bars.

Well fortunately, there’s always something new to discover, and it’s right there where... The evolution begins…

Sliding roofs on trailers

Already at the very beginning of the first regulations (DCE 9.5, VDI 2700…), trailer builders discovered that sliding roofs were a week part in the total superstructure of a trailer. As the roof system is designed to open smoothly under all circumstances, a lot of spaces and tolerances are included in the system to make the rollers run. This is in absolute contradiction with the strength and structural rigidity, which is imposed to comply with the EN 12642XL norm.

A sliding roof is an important part of the total strength of the superstructure. For this reason, several different types of reinforcements have been tested or even patented. The simplest solution is to reinforce the roof with diagonal steel pipes. These pipes are fixed between the aluminum sections. Unfortunately, the driver needs to remove these pipes every time he has to open the sliding roof. This is a very dangerous and time-consuming process, as he has to climb up on his trailer to remove these pipes manually. Another well known system, are the patented stainless steel wires which are fixed diagonally under the roof.

As opposed to the steel bars, the wires slide open together with the opening of the roof, but they hang into the trailersʼ loading space like spider web.

Besides the high cost of these special stainless steel wires, another important problem is the damage they cause to the aluminum sections. Due to the fact that the whole system is built on 4 or 8 wires for the whole roof, all the centrifugal forces are divided over only 2 or 4 points along the aluminum sections at each side of the roof. For this reason, all the horizontal rollers in this system have been replaced by massive steel blocks. Besides the fact that these blocks are damaging the aluminum sections, they do not allow an easy opening of the roof, as it would be the case with the original rollers. Last but not least, due to the frequent damages the wires are creating, a lot of trailer builders install the wires without tensioning them. This will of course reduce the damages to the roof, but the superstructure will not be strong enough to keep the goods into the trailer in case of an accident.

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A close-up on the Carapax® System

Carapax® is a revolutionary patented concept: basically, what assures the safety and the superior strength of an aircraft, a military helmet or a bullet proof vest, has been welded right into the roof curtain of the trailer, providing an unmatched strength to the trailers’ superstructure. Aramid fibers are particularly light, yet incredibly strong. Aramid fibers can be laid into sheets of fabric with the exclusive advantage of obtaining composite materials which are five times stronger than stainless steel, heat resistant up to 500° C but softer than your blue jeans!

No wires are hanging in the loading space of the trailer when the roof is open.

The aramid reinforcement is welded into the roof curtain. This patented construction just works like a carapax of a turtle over the trailer: the extreme strength of the roof curtain has a positive influence upon the lateral resistance, helping the body structure to comply with the highly demanding EN 12642XL regulation. The molecular structure and the way the aramid fibre itself is spun, provide an incomparable strength but also allow the elastic stresses to be evenly spread over the length of the trailers’ superstructure. The composite material increases the trailer strength, without making it heavier.

DYNATEX protected the Carapax concept with the European Patent EP2001694: « reinforcement material and roof stabilisation system to prevent deformation of chargers, trailers and/or lorries »