For underground utility contractors, the ability to move tools, equipment, and crews efficiently between jobsites is not just a convenience it is a operational necessity. When standard off-the-shelf trailer solutions fall short, a custom approach can transform productivity and responsiveness. This case study examines how Burschville Construction, Inc. partnered with Felling Trailers to develop a custom enclosed trailer chassis that solved longstanding mobility and accessibility challenges. The principles behind this build offer valuable insight for any contractor evaluating Hydraulic Trailers and specialized hauling equipment for their fleet.
The Limitations of Standard Utility Trailers
Burschville Construction, Inc., an underground utility contractor based in Minnesota, had been using semi-van trailers to store and transport crew tools and equipment. While these semi vans could hold the necessary gear, they introduced significant operational friction. Crew members had to climb stairs to enter and exit the trailer, and every move between jobsites required scheduling a semi-truck and driver. This dependency created delays and reduced the flexibility that utility work demands, especially when responding to emergency repair calls.
Why Off-the-Shelf Trailers Did Not Fit
The challenges Burschville faced are common among utility contractors who need enclosed trailer space but operate in environments that standard products are not designed for. Key pain points included:
- Mobility constraints Moving a semi-van required coordinating with a semi-truck driver, adding hours or days to relocation timelines.
- Access difficulties Stairs made entering and exiting the trailer cumbersome, especially when crews needed quick access to tools.
- Jobsite adaptability Semi-vans were difficult to position on tight or uneven jobsites, limiting where they could be parked and used.
- Foreman tool availability Tools stored in a central semivan were not always accessible when a foreman needed them for emergency calls.
These issues are not unique to Burschville. Many contractors find that standard equipment trailers force compromises between storage capacity and day-to-day usability. Understanding when a custom build is warranted starts with a clear assessment of operational requirements. For background on project approval processes, see Who Should Apply for a Building Permit Owner for guidance on contractor responsibilities.
Evaluating the Case for a Custom Build
Burschville already owned five deck-over Felling Trailers and had positive long-term experience with the brand. When the need for an enclosed trailer arose, the company evaluated whether a custom chassis could replace their semi-van approach. The decision hinged on several factors:
- Previous Felling trailers had held up well under demanding conditions.
- The trailers pulled well on highways and secondary roads.
- Customer support from both Felling and the local dealership Lano Equipment was responsive and reliable.
- Felling was a Minnesota-based manufacturer located only 70 miles from the Burschville office, ensuring fast parts availability.
Engineering the Custom Trailer Chassis
Burschville wanted a custom-built trailer chassis that would then be taken to a commercial truck bodybuilder for the installation of an all-aluminum enclosed body. This two-phase approach required the chassis to meet exacting structural standards. An inadequately stiff frame would flex and twist under load, transferring that movement to the aluminum body above and causing eventual failure of the enclosed structure.
Structural Design and Frame Specifications
Felling’s engineering team, led by Mark Rapp, utility/telecom product manager, worked closely with Richard Schendel, vice president of Burschville Construction, to define the specifications. The collaboration involved multiple meetings and extensive email exchanges to ensure every requirement was addressed before production began.
The resulting design targeted a gross vehicle weight rating (GVWR) of 24,000 lbs. To achieve this capacity while maintaining proper towing characteristics, Felling specified a triple 8,000 lb. axle configuration. According to Mark Rapp, the triple 8,000 lb. axle setup with a 26.5 ft. bed length was more forgiving in achieving the correct tongue weight for good towing behavior compared to a 12,000 lb. tandem axle arrangement. The perimeter of the chassis frame required particular attention. Felling used laser-cut 3/8 in. steel plate that was formed to provide the structural support needed along the edges. Outriggers were installed every 16 to 18 inches, carefully aligned with the cross-members between the mainframe rails. This approach ensured the perimeter could support not only the weight of the aluminum body but also the shelving units and other equipment that would be mounted along the side walls.
Key Specifications and Design Decisions
| Parameter | Specification | Design Rationale |
|---|---|---|
| Gross Vehicle Weight Rating | 24,000 lbs. | Sufficient capacity for tools, equipment, and aluminum body structure |
| Axle Configuration | Triple 8,000 lb. axles | Better tongue weight distribution than tandem 12,000 lb. axles |
| Bed Length | 26.5 ft. | Matched to the enclosed body dimensions and load distribution needs |
| Frame Perimeter Material | 3/8 in. laser-cut steel plate | Precision-formed for structural support along side walls |
| Outrigger Spacing | 16-18 in. on center | Aligned with cross-members to distribute load evenly |
| Floor Surface (side areas) | Heavy expanded metal | Durable, slip-resistant surface at side door and rear roll-up door |
The structural plate served a dual purpose. It functioned as the floor surface outside the mainframe rails and provided the strength needed to tie the aluminum body securely to the chassis. A pull-out step and heavy expanded metal surfaces were installed at the side door and across the full width of the rear roll-up door to improve crew safety and ease of access. For a deeper look at related structural engineering principles, refer to Engineering a Ventilation Solution for Wind Driven Rain.
Upper Body Integration and Final Assembly
Once Felling completed the trailer chassis, it was transported to Ohnsorg Truck Body in Belle Plaine, Minnesota, for the installation of the all-aluminum enclosed upper body. John Ohnsorg and his crew handled the body fabrication and integration, transforming the rolling chassis into a complete enclosed trailer solution. This division of labor allowed each specialist to focus on its area of expertise: Felling on the heavy-duty chassis and running gear, Ohnsorg on the lightweight yet durable aluminum enclosure.
Completed Trailer Features
- All-aluminum enclosed body mounted on a reinforced steel chassis.
- Roll-up rear door for full-width loading and unloading.
- Side door with pull-out step for easy crew access.
- Expanded metal flooring at entry points for traction and durability.
- Interior shelving supported by the reinforced perimeter frame.
The end result was a purpose-built trailer that matched the storage capacity of the previous semi-van while eliminating the operational drawbacks. To understand how similar equipment is deployed in concrete work, see Understanding Trailer Mounted Concrete Pumps for a related equipment discussion.
Operational Benefits and Return on Investment
The switch from a semi-van to a custom enclosed trailer pulled by a standard Super Duty truck produced measurable improvements in Burschville’s daily operations. Richard Schendel noted that the company could now move the same tools and equipment using a foreman’s company truck rather than scheduling a semi-tractor for every relocation.
Measurable Improvements
- Eliminated semi-truck scheduling Foremen can tow the trailer directly with their company pickup, cutting move times from hours to minutes.
- Improved jobsite access The pickup and trailer combination can navigate tight or soft ground conditions where a semi-van could not go.
- Tools always with the crew Each foreman keeps the tools on-site and available, enabling faster response to emergency repair calls.
- Enhanced municipal service Prompt response times have been noticed and appreciated by the municipalities Burschville serves.
- Lower operating cost Eliminating semi-truck transport for the trailer reduces fuel consumption and labor costs.
The Value of Local Partnerships
Schendel emphasized the importance of having a responsive dealer network. Lano Equipment in Loretto, Minnesota, located just 10 minutes from the Burschville office, provided the sales support and service that made the custom project feasible. Salesman Bill Lano, who had sold Burschville its first new Felling trailer years earlier, ensured the custom build met all expectations. The proximity of both the dealership and the Felling factory meant that parts and support were never far away, a significant advantage when downtime costs can run high.
Since purchasing the custom enclosed trailer, Burschville has added another Felling deck-over trailer to its fleet with further customizations. This repeat purchase reflects the operational value the company has realized from working with manufacturers and dealers who understand the specific demands of utility construction work.
Lessons for Contractors Considering Custom Trailers
The Burschville-Felling collaboration illustrates several principles that apply to any contractor evaluating a custom trailer investment.
- Start with the operational problem, not the trailer. Identify the specific mobility, access, and storage constraints before specifying the solution.
- Engage the manufacturer early. Involving the product manager in the design phase ensures that engineering decisions align with real-world use.
- Plan for chassis-body integration. When using separate specialists for chassis and body, communicate load paths and attachment points clearly between both parties.
- Prioritize frame stiffness. For enclosed bodies, an inadequately rigid chassis will transfer flex to the body structure, leading to premature failure.
- Factor in dealer proximity. A nearby dealership that stocks parts and provides service is an asset that reduces downtime over the life of the trailer.
- Test tongue weight and towing behavior. Axle configuration and bed length directly affect how the trailer handles on the road, especially with enclosed bodies that add weight above the frame.
Custom trailers represent a higher upfront investment than standard models, but for contractors whose operations are constrained by off-the-shelf solutions, the productivity gains, reduced labor costs, and improved response times can deliver a strong return. When evaluated through the lens of total cost of ownership including the value of faster jobsite moves, better crew access, and eliminated semi-truck scheduling the custom approach often proves to be the more economical choice over the long term. Whether a contractor needs a simple deck-over design or a complex enclosed build like Burschville’s, starting with a clear understanding of operational requirements and working with experienced manufacturers ensures the final trailer delivers exactly what the job demands.