At Ace, we’ll be the first to admit: no piece of equipment is ever truly “finished.” There is always room to improve, to make it stronger, lighter, more reliable, and easier to operate in real-world conditions.
We’re fortunate to work with a loyal group of customers who don’t hesitate to share feedback, pain points, and ideas from the field. And honestly, who knows equipment better than the people running it day in and day out?
Because of that feedback, 2025 brought several meaningful design upgrades across our roll-off trailers and lugger hoists. These changes improve lifting performance, durability, compliance, and overall efficiency.
Here’s a look at what changed and why it matters.
Upgraded Telescopic Cylinders: More Power, Better Sealing
For nearly 30 years, Ace has used a custom-built 4-stage telescopic cylinder manufactured by Custom Hoist. This cylinder delivered approximately 88,000 lbs of lifting force at 2,100 PSI and has performed reliably across thousands of units.
In 2025, we upgraded the internal design to allow operation at 2,500 PSI and incorporated positive seals instead of traditional piston ring seals.
Why this matters:
- Higher operating pressure = more lifting force for heavier containers and tougher loads
- Positive seals reduce the risk of cylinder leakage, a common issue in piston-ring designs
- Improved reliability and longer service life
This additional 400 PSI gives our roll-off trailers the extra muscle needed for today’s heavier applications without sacrificing durability.
D-Plate Redesign: Improved Lift Geometry & Tighter Tolerances
The D-Plate (our internal name for the hinge point where the draft arms attach to the trailer frame) has evolved over the years.
- Early design: Collar and pin system with a bolt-on retaining ear
- 2010 update: Weld-in pin design to simplify assembly
However, feedback from the field showed that under heavier loads:
- The front of the trailer sometimes struggled to lift properly
- The weld-in design allowed the front frame saddles to catch on the fifth wheel plate collars
After reviewing the data and customer feedback, we returned to the pin-and-ear design, which allows for tighter tolerances and better control of frame movement.
Paired with the upgraded telescopic cylinders, this redesign eliminates lifting issues under heavy loads and improves overall trailer geometry and consistency.
Bumper Redesign: Stronger Mounting for Real-World Impacts
In 2025, we redesigned the bumper cylinder mounting bracket.
Previously, the bumper cylinder was mounted using a welded stud. In certain impact situations, such as contacting a container or the ground at the wrong angle, the stud could bend or break.
The new bracket design:
- Distributes load across multiple mounting points
- Reduces stress concentration on a single stud
- Significantly improves durability and impact resistance
This update greatly reduces the likelihood of bumper actuator damage in the field.
Bumper Data Tag Upgrade: Permanent Compliance
Since 2004, ICC bumpers have been required on trailers where the frame extends more than 12 inches past the tires. Ace has continued to refine bumper strength and compliance over the years.
Our current bumper design uses 3/8″ steel tubing, exceeding the 3/16″ minimum requirement specified by FMVSS regulations.
Regulations also require a manufacturer compliance data tag on every bumper. Previously, we used an adhesive-mounted metal tag. In harsh operating environments, the adhesive could fail and the tag could fall off.
In 2025, we upgraded to a riveted data tag, ensuring permanent attachment and long-term regulatory compliance, even in tough working conditions.
Suspension Hanger Redesign: Lighter, Stronger, Faster to Build
Early in 2025, our engineering team challenged themselves with one goal: reduce weight without compromising strength or safety.
One major opportunity was the suspension hanger, a design that had remained largely unchanged for over 30 years. While proven, it was:
- Heavy
- Expensive to manufacture
- Time-consuming to fabricate
The new suspension hanger design:
- Reduced weight by 180 lbs
- Increased safety factor by 207%
- Improved manufacturability and production efficiency
This means lighter trailers, stronger components, and faster production, a win across the board.
New Suspension System: Same Capacity, Less Weight
Since 2008, Ace has relied on the Hutchens H-900 7-leaf, 50,000-lb single point suspension, a rugged system with excellent long-term durability and minimal maintenance.
Hutchens recently introduced their tapered 3-leaf spring suspension, maintaining the same 50,000-lb rating while reducing weight by nearly 400 lbs.
We integrated this new suspension into our redesigned hanger system, and feedback has been overwhelmingly positive. The result is:
- Significant overall weight reduction
- Maintained load capacity
- Improved efficiency and performance
Looking Ahead to 2026
These upgrades represent just a snapshot of how customer feedback directly shapes Ace equipment.
We’re already looking forward to what 2026 will bring and we welcome your input. If there’s a pain point, idea, or opportunity for improvement on any Ace product, don’t hesitate to let us know.
Because the best equipment is built in partnership with the people who use it every day.
