The AeroWall has seen more than 1 million miles of operation including extensive on-the-road testing. On-road testing generally yields much lower results than controlled track testing, because the vehicles are subject to real-world road conditions and do not benefit from testing only when the vehicle is moving at typical highway speeds. The AeroWall saved an average of 4.9% in on-road test conditions consistent with SAE J1321.
The AeroWall is even more efficient in cross winds. Although the AeroWall does not improve fuel efficiency in crosswinds, fuel efficiency will degrade far less with the AeroWall than a tractor that is not equipped with the AeroWall. The fuel savings calculation is derived from decreased fuel consumption plus the loss of degradation due to crosswinds when comparing an AeroWall-equipped truck to a truck without one.
Prior to the AeroWall, fleets would pay a big penalty in fuel consumption to maintain or widen the gap area
The most common solution to reducing drag in the gap is to draw the trailer tight to the tractor and to deflect air movement away from the trailer edges using side cab fairings. Narrowing the gap creates gains in fuel efficiency, but it also compromises safety, driver comfort, and increases operating costs. Placing the fifth wheel in the optimal position for weight distribution widens the gap, which improves handling, extends tire life, and decreases damage and expensive repairs to side cab fairings. The AeroWall allows fleets to widen the gap without compromising fuel economy, especially at speeds greater than 50mph.