Durability, speed, adaptability, and liability are four concerns haulers have with tarps and tarping systems. Manufacturers have been addressing those concerns. Here's how.

By Joseph Lynn Tilton

Time was when waste haulers focused mainly on getting their loads to the destination safely. Nobody ever wanted to make the wrong kind of headlines, nor did they ever want to have a workers' comp claim to deal with. Now, thanks to EPA regulations as well as heightened public interest and the need to maintain a good reputation, haulers rely on tarps and tarping systems to help them safely, quickly, and easily cover a load of diverse containers before they leave the transfer station or other pickup point. That's so there's no mishap or lengthy time spent during loading or unloading and not even a shred of evidence left on the roadside to show their passing.

Pioneering Tarping Cover Systems

"We invented the automatic truck cover," declares Lenny Brescia, executive vice president and co-owner of Pioneer Cover-All in Oxford, MA. "We are the pioneers of automatic tarping systems and were awarded the first truck-covering-system US patent ever. One of the main reasons we have experienced explosive growth is because of the environmental concerns. Haulers can't afford to lose their load. Littering is prohibited in most civilized parts of the world, especially in major cities and tourist areas. It's just not acceptable to have material escape from loads."

Brescia, who started with Pioneer 23 years ago as sales manager of the refuse division, says that Pioneer was incorporated in the late 1960s. He adds that the first tarping systems were slower, more fragile. Fortunately, that has changed. "In the past 30 years, the technology has improved. We've explored different powered systems. The first were electric; now we utilize hydraulics, air, and different technologies for the 8,000 tarping systems we sell per year."

Pioneer, the largest manufacturer in the United States of tarping systems for rolloff trucks has two divisions—one that focuses on the waste industry and one that deals with construction. Unique to Pioneer is a rack-and-pinion system that makes up roughly 60% of its total sales of tarping systems. "Years ago, it would take 35 to 40 seconds to cover a typical load. Today, our rack-and-pinion system can cover a load in about eight seconds. In addition, systems today are more versatile and stronger. New materials have improved the fabrics available for tarps to help increase longevity. The fabrics today are more difficult to tear; they hold up much better."

Brescia comments that Pioneer has developed systems for different applications, whether the load is gravel, hot asphalt, demolition, refuse, or scrap steel. "Scrap steel is sharp and highly irregular, so it's one of the most challenging loads to handle. When haulers can increase productivity, operate safely, and preserve the environment, it's a winning combination." He explains that most major waste companies typically replace their vehicles every eight years. That is usually an ideal time for updating the tarping system.

As with all other activities, operator error is a concern. Brescia says, "It is important that companies include maintenance management as part of their driver education and supply their operators with video instructions available from Pioneer. Proper operation is essential to getting the most out of any system."

When asked what's new with Pioneer, Brescia points out that the company holds 24 world patents or patents pending, but its latest device, the Skip-Cover, will be marketed in 13 European countries. A "Skip" is a vehicle used for transporting refuse or solid waste in smaller containers and is designed for smaller vehicles. This vehicle is utilized throughout Europe where the roadways are much more narrow than here in the United States. The Skip-Cover provides a semiautomatic alternative, which provides greater safety and productivity than manually covering the load.

Hand Tarping Has Its Niche

While automatic systems are popular, there still is a need for tarps that can be applied by hand in some applications, explains Glenn Ray, vice president of sales for Pulltarps Manufacturing Inc. in El Cajon, CA. This company has a manufacturing facility in El Cajon as well as a second one 850 miles away in Denver, CO. Its 55 employees make both tarps and tarping systems. "Hand tarping still is popular for rolloff containers and small trailers used for landscaping and yard waste."

When asked about the challenges he sees in the industry, Ray responds, "There are a couple of things to deal with. The tarp system itself is the most fragile part of the vehicle and works in an extremely harsh environment. It's usually damaged if not used properly. One of the issues involves large transfer trailers. Normally, when they're being loaded those larger trailers get damaged by the loader operator or by the weight of the load itself. That weight actually bows out the walls of the trailer, which makes it extremely difficult to put a tarp or a tarp system on."

Ray then explains that Pulltarps' focus is on the demolition side of construction, with its solid-waste applications in a few crossover areas. He comments, "Waste hauling isn't our bread and butter, but construction is the core of our business. Construction companies are using tarping more and more because legislation requires they cover or contain the load. It's really no different than the waste industry, and when it comes to tarp or tarp system damage, the loader usually is the biggest culprit. As long as the operator pays attention to what he's doing, the chance for damage to tarps or tarping systems is greatly reduced." But it takes just a few seconds of inattention to allow the bucket to come in contact with a tarping system-and heavy metal always comes out the winner.

Keeping the Vision

The Mantis seals the load by pivoting the tarp roller down to the hoist rails.

"One of the primary challenges for the hauler is covering the load effectively," agrees Scot Fuhrman, waste cover division manager for Donovan Enterprises in Stuart, FL. "Sometimes that gets caught up in bells and whistles, but the primary need is to cover the container, make the tarper a safe system for the driver, and make it quick to operate and easy to maintain. No matter what you do, you're going to have time and maintenance challenges, so you want a system that is simple, quick, and affordable."

Fuhrman reports this is what prompted Donovan to introduce the Mantis at WasteExpo 2003 in New Orleans, LA. "We had units in the field with national haulers nine months prior to the show, and user reaction has been fantastic. First thing about the Mantis is clear visibility. It's the only gantryless automatic rolloff tarper on the market. Its resting location behind the cab is below the window."

He says that the system's range of motion allows every container to be covered, yet the roller still rests on either the container or the hoist rail. "This gives greater assurance of keeping the load inside the box while traveling at freeway speeds. It also prevents damage that occurs to the tarp and to the mechanism when the roller is extended past the container but isn't supported."

Asked how the company came up with the name "Mantis," Fuhrman responds, "When we were installing the first unit the shop mechanics said it looked like a grasshopper. But grasshopper is too long to fit on a modest-sized sticker, so we chose a shorter name that still reflects on the machine's profile." He adds that the goal is to make it possible for operators to pick up any size container—thus the need for a system that could safely tarp containers as short as 10 to 17 feet yet avoid the damage that is possible when a tarp system is too long.

"With the Mantis, if the load is shorter than 17 feet, the tarp roller goes over the container and rests directly on the hoist rail, which gives it a better seal and prevents damage to the tarp and system that's caused by bouncing. With 20- to 40-cubic-yard containers, the system rests on the back edge of the container." Also critical to Donovan's success is manufacturing its own tarps, which it engineers for use with the mechanism. "By manufacturing in-house we have closer, more clear, and quicker communication—and greater accountability. We meet weekly, and even more frequently when designing a system to fit a specific customer's need."

Fuhrman emphasizes that his company has 27 sales reps across the country and 13 more in Canada. "We provide sales reps with product information all the way down to commonly asked questions, exploded-parts information, drawing diagrams, brochures, all that's necessary for them to have a thorough understanding of the products they're repping. Plus, we have an in-house engineering team available for immediate use. If a customer has a need we can have a person to them the same day or inside of a week for sure."

He cites the example of a dealer in the Northeast, who had a major customer interested in changing systems, but the dealer didn't have the necessary equipment, nor was he in position to replace major fixtures so he could quickly take care of his customer. "The dealer contacted our sales rep in that area and our rep had one of our engineers fly up from Florida. They spent an entire day at the dealer's shop, finishing at 3:00 a.m., and were able to modify the mounting design that allowed for our dealer to quickly and effectively install Mantises using the current equipment and fixtures in his shop."

The engineer first checked out the shop's fixtures and tools for installing tarper systems, checked out what the hauler had on his vehicles, and then installed bracing to the dealer could use his existing fixtures for mounting the new tarper. "By making those changes, the dealer reduced installation time from 24 to 30 man-hours per vehicle down to 16 to 20. He was better equipped to help one of his major customers. There was less waiting for each installation, and everybody won."

Electric Kit Helps Keep It Fast, Safe, and Easy

Adjustable components help Roll-Rite tarps cover loads safer and easier.

As with other manufacturers, Roll-Rite Corporation in Alger, MI, meets a host of applications with its tarping-system line. For rolloff applications, the company offers a number of patented components and systems featuring both stationary and adjustable features. "Tarp issues and concerns are not unique to waste haulers," says Cindy Cook, marketing manager for Roll-Rite. "All tarp users want longer product life as well as easier installation and operation." For easier installation, the firm reports an across-the-board change with its 1080 Rocker Switch Electric Kit, which runs a more flexible 14-gauge, three-conductor wire to the cab.

Asked what makes the company's line different from the competition, Cook says, "There are other arm-style tarp systems; however, our patented aluminum arms do not have hydraulics, which makes them more cost-effective to replace in cases of damage. A hydraulic spill is a waste hauler's worst scenario. Any hydraulics in our adjustable systems are self-contained low in the pivot mount—that way, if damage does occur to our arms, there is much less chance of a hydraulic spill." She reports that these adjustable units are primarily useful for users transporting a wide range of multiple-size containers.

The 1080 is also relatively simple to install and learn to operate. "Depending on the model of the vehicle, an average install can take up to a day. Some custom applications require more install time. An average person can learn how to operate it within 10 to 15 minutes." The company warrants all of its products free of defects under normal use and service for one year. In addition, its gear motors carry three- to five-year warranties against wear-out, depending on the specific model.

Roll-Rite systems adapt to a wide range of container sizes.

The latest design improvement to Roll-Rite's systems for rolloffs is a tapered adjustable-pivot component. "Its triangular design is an easier install and a better fit for many older-style rolloff trucks still being used in the field," Cook explains.

"When dealing with any mechanical tarp system, in some cases tying the tarp down to keep the load inside is just a wise choice. Users should evaluate their load and weather conditions. An extra 10 to 20 minutes for a couple of straps on each side helps provide extra assurance that the hauler will get to the destination with the whole load."

Roll-Rite also offers a variety of tarp fabrics, including heavier grades designed for dealing with heavy waste and scrap debris. "It's a 14.2-ounce poly-type fabric that is three to five times stronger than other general mesh fabrics," Cook describes. Since its introduction two years ago, that heavy-duty mesh has proven popular with metal-scrap haulers.

Asked what counsel she would give haulers, Cook replies, "When making an investment in an automatic tarp unit, be sure to compare component repair and replacement costs. These costs, along with any potential labor maintenance, help determine true value of any brand system." Dealing with real numbers may take more time than optimistic estimates, but real numbers help ensure that a waste-hauling company doesn't get a financial black eye over the product's lifespan.

Replacement Tarps for All Systems

THOR can configure a high-temperature tarp in any size, shape, or weight.

The THOR Tarp Division of Odin International is based in Austin, TX, and supplies replacement tarps rather than focusing on hardware, explains David Urban, division vice president. Speaking from 18 years in the industry, he comments that the biggest challenge for waste haulers in the United States is keeping up with environmental regulations, whether local, state, or national. So how does THOR help in this? "Basically, we make sure the customer gets the right material in the right configuration. We can supply replacement tarps in a time flow of anything from overnight to two weeks, depending on the specific need and factory time schedule."

The firm posts $5 million in annual sales and 95% of its market is within the United States. Urban notes that when the company gets a request for a replacement tarp the first thing it determines is the customer's focus. "What are you hauling? Rolloff containers can get by with economical tarping material, and they make up 70% of the marketplace right now. Sturdier material, though, is needed as containers get longer and bigger." There's a lot of stress on the mound when the vehicle is driving down the Interstate at 75 miles per hour. Furthermore, a high mound is not aerodynamically sound and can lengthen the time it takes to get to the vehicle's destination.

One of the solutions is to utilize a knit polyester material so the vehicle is not slowed by the wind factor. "That mesh lets the wind out but keeps the waste material in," Urban explains. He adds that local hauls, which don't involve long distances or high-speed moves, typically can use material as light as 11 strands per square inch, while tarps designed for long hauls have round holes ranging from 0.25 to 0.5 inch in diameter, which again keeps the material in and lets only the air out.

He warns, "On top of a citation for whatever else flew out, if a hazardous substance such as a gallon of used motor oil hits the side of the road, a hauler could end up spending a lot of time in court." That's why he advises those hauling hazardous material to use tarps that are completely waterproof and can handle the stress of compaction. This compaction not only ensures maximum loads per haul, but it also minimizes the tarp flapping up and down.

But how does a hauler replace the old tarp? Urban replies, "Basically, we tell them to put the new tarp back on the way they took the old one off their tarping system. Some steady users appreciate lower overall tarp-life costs, so instead of grommets on one layer of material we also put webbing around the edges to give those grommets more material, helping them better handle any stress from tied-down loads. They're folded accordion-style on the width and the operator has to pull up only any wings involved. This helps make one tarp adjustable for any load length." Customer preference is why THOR offers eight different kinds of materials in its line.

When asked about hauling mistakes he's seen, Urban comments, "The most common is not tying down the tarp correctly, which leads to a lot of flag waving and shredding. In those cases, it's usually where the tarp meets the corners of the containers that gets the most abuse, especially in the back two corners. If that's not corrected, it leads to tarp shredding and an earlier-than-expected replacement."

Urban says that over the years he's noticed a lot of "parachuting" by an improperly secured tarp. "Haulers need to worry about their name, reputation, the people behind them, and the consequences of improperly covering that load. Otherwise, they're the type that tends to stay a one-man operation or go out of business. A good operator takes into account his loads, the weather, the traffic flow, and the fact that the name of his company is on the side of his truck. He's advertising as he carries his load. A good tarp or tarping system helps ensure a good reputation." Furthermore, those who try to be too economical with tarps and tarping systems end up wasting their funds because they're spending more money on replacement tarps, losing loads, creating headlines, answering court summonses, and so on.

Keeping the Driver Grounded

Woody O'Brian, president of O'Brian Tarping Systems in Wilson, NC, reports that for longest-possible tarp and tarping-system life, the driver needs to be sure the loads are flat before they're covered. It doesn't matter whether it's heavy metal or paper goods—projections injure tarps and can lead to damage of the system used to put the tarp in place.

O'Brian notes that he's the third generation in his family firm, which has about 30 full-time employees making square tarps, hand tarps, and tarps for ag use as well as an articulated elbow for the solid-waste industry. "That elbow allows adjustments for different-size boxes and different-size containers. It's operated by a one-handle joystick control and after three to four trips the first-time user is fully comfortable with the system."

When asked how to maximize tarp life, he responds that one of the best things to do is to keep the driver on the ground where he can pay attention to his load. "Again, the driver needs to smooth the top of the load if at all possible. With our system he can use a battering ram to move some of the load around yet stay on the ground. A $160 stabilizer bar is a whole lot cheaper than a workers' comp claim."

O'Brian says that when not in use, the roller needs to be supported or fatigue will shorten the tarp and reduce the life of both the tarp and the tarping system. "Keep it supported at all times, regardless of the tarping system. The roller has got to be supported or you'll have high maintenance costs."

He also notes that haulers with a solid preventive-maintenance program tend to take better care of their tarps and the tarping systems. "The kind of care they give their trucks is the kind of care they tend to give their tarping systems. If trucks get considerable maintenance, then a tarp system that calls for scheduled maintenance makes sense because it's going to be checked when the mechanic checks the vehicle." If maintenance is lax, then the hauling company may find maintenance-free tarping systems more economical in the long run. "If you don't like to do maintenance, then spend a little more money and save on the maintenance end. It gets back to individual choice."

When buying a tarping system, another consideration is the container typically used. "Are you using multiple-sized containers or do they tend to be the same size? If all are the same size you don't have to have a tarping system with adjustability—just get one that fits the box size you're using. If you have a large variety of container sizes then you need a tarping system to accommodate all those containers. Again, the goal is to keep your driver on the ground."

He notes, for example, that his company has a tarping system line that is slow at takeoff, fast on the go, and slow at removal. "Yet, with inside controls, the driver doesn't have to stand outside during the tarping process. The less time a driver spends out of the truck the less chance he has of getting hurt or talking with his buddies at the landfill." Generally speaking, the driver will spend less time in the landfill even with a slower-moving tarping system because neither physical movement nor conversational temptation intervenes.

So it is that no matter what's needed in tarps or tarping systems, US manufacturers can not only meet the desired specs of solid-waste hauling operations of any size but help those companies avoid unhealthy headlines, environmental and legal woes, or medical expenses brought on by workers' comp claims. 

Journalist and frequent contributor Joseph Lynn Tilton specializes in waste and transport issues.

MSW - September/October 2004