Case Studies
Engineering innovation behind Borcat’s Live Bottom Trailers
Engineering innovation behind Borcat’s Live Bottom Trailers
Borcat Trailers has been a trusted name in New South Wales since the late 1950s, building reliable and lightweight tipper bodies that deliver lasting value for operators who need equipment they can count on in demanding conditions.
In 2024, Borcat, in conjunction with Haulmark Trailers, became the New South Wales sales and service dealer for Gincor Live Bottom Trailers, bringing this proven Canadian design to local customers through Haulmark’s import partnership. The live bottom system has more than 40 years of development behind it and can handle an impressive array of materials, from hotmix asphalt, gravel, and sand to agricultural products, mining materials, chemical fertilisers, dry lime, potash, calcium, coke/fly ash, and millings.
“Live bottom trailers are more prevalent today than they were ten years ago, so we just want to supply our customers with another high-quality option,” says Borcat Managing Director, Paul Gallagher.
Borcat partnered with Transport Engineering Solutions to handle the hydraulic installation that allows the Live Bottom Trailer to lift for servicing and maintenance access. TES supplied and integrated the tipping and control system, ensuring reliable operation and a clean, professional finish consistent with Borcat’s build standards.
The Challenge: Engineering a Smarter, More Serviceable Live Bottom Trailer
Borcat didn’t want simply to supply a live bottom product. From the start, they had ideas about custom tipping capability, maintainability, and service access that went beyond standard design. Their goal was a truck-mounted Live Bottom Truck Body which could also tilt, allowing full access underneath for cleaning, servicing, and component replacement.
“TES was our first choice for this application,” Paul says. “Steve has a good handle on hydraulics and his recommendation to our questions resulted in a smart underbody hoist arrangement which packaged and presented well.”
Adapting the Canadian-built Gincor body required only minor tweaks to Borcat’s subframe, with no significant redesigns or testing. “There were no real challenges coupling the body to the truck, just a few small changes to our subframe,” Paul explains. “The install was seamless.”
TES’s Involvement and Solution
TES brought a full suite of hydraulic and pneumatic capabilities to the project. The team supplied the Binotto high trunnion hoist kit, OMFB PTO and pump system, CBS valve, diverter and tipper valves, and the pneumatic control box, all configured to match Borcat’s specifications and ensure safe, consistent operation.
“TES has had a long relationship with Borcat,” says Steve Lakin, State Sales Manager at TES. “With strong engineering and a diverse product offering, all challenges were met.”
Borcat incorporated its own air-operated body prop, a standard feature from its rigid body designs, ensuring safe access under the body for cleaning and maintenance. TES engineered the remaining hydraulic circuits, ensuring correct mounting geometry, load distribution, and smooth control logic.
“With the ability to work closely on the Front-End Engineering Design process, we can communicate and resolve any challenges,” Steve adds. “Having peace of mind knowing both parties are on the same page makes all the difference.”
The Result
The final outcome is Australia’s first Gincor Live–Bottom truck body capable of tipping, combining the clean discharge of a conveyor system with the serviceability of a traditional tipper.
“To most, the thought of a live-bottom truck body ‘tipping’ doesn’t make sense… until you need to work on or clean one,” Paul says. “The cost savings by not having to disconnect electrics and hydraulics or remove the body for maintenance provide an unrealised gain over the life of the vehicle.”
The first unit, sold to Townsville Mini Loads through Mack Trucks Brisbane, drew strong attention before it even left Borcat’s facility. A second unit is now in build and will head north later this year.
“Being able to achieve the result my customer needs, and knowing they can rely on me, that’s the part I’m most proud of,” Steve says.
Why It Matters
This project shows how collaboration between manufacturer and systems integrator can deliver something genuinely new to the market. By combining Borcat’s fabrication expertise with TES’s hydraulic and control knowledge, the team created a product that offers better safety, accessibility, and lifetime value for Australian operators.
The partnership delivered a unique product and set a benchmark for collaboration between OEMs and system suppliers in the transport engineering space.
Results & Impact
- Australian-first Gincor Live Bottom Trailer with tipping capability: This design drew attention across the industry, especially among asphalt and hot mix users who need both the advantages of live bottom unloading and the ability to clean and service the truck underside.
- Strong collaboration between fabricator and systems integrator: The success of the project came from Borcat’s fabrication expertise working hand in hand with TES’s hydraulic, valve, and control system knowledge.
- Low disruption, high capability: the final system achieved ease of service, minimal chassis modification, and strong operational performance, proving the value of early collaboration between manufacturer and system supplier.
- Seamless integration of Binotto and OMFB hydraulic systems
- Improved service access and reduced maintenance downtime
- Demonstrates TES’s strength in supporting OEM partners through collaborative engineering
Need a trusted engineering partner for your next trailer build?
Contact TES to discuss hydraulic, tipping, or control system solutions.
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Example Case Study
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