How to Set Up and Operate a BurnBoss Air Curtain Burner

The BurnBoss T24 is a forced-air incinerator that safely reduces wood waste on-site without environmental violations. Whether you're managing forest slash, limbs, bark, or untreated lumber, the BurnBoss reduces material volume by 97% in a single pass. But operation requires precision. Improper setup, overloading, or burning prohibited materials can cost you permits, trigger EPA citations, or worse—create a safety hazard. This guide walks you through every step: site selection, startup, loading technique, safety protocols, and Pennsylvania compliance.

What the BurnBoss T24 Does

The BurnBoss T24 is a forced-air combustion chamber mounted on a street-legal trailer. Think of it as a high-efficiency industrial incinerator designed specifically for wood waste on job sites and in yards. The core technology: a two-cylinder diesel engine powers a massive fan that pushes a curtain of air across the top of the firebox at 12 feet wide, 4 feet deep, and 4 feet tall. This air curtain reaches temperatures between 1,800°F and 2,400°F, creating complete combustion with virtually no smoke.

The results are dramatic. What would take a pile-burning operation hours or days, the BurnBoss handles in minutes. A 97% volume reduction means a full trailer load of brush, limbs, and slash burns down to roughly a bucket of biochar. The machine processes 5 to 10 cubic yards of forest waste per hour, depending on material size and moisture content. The entire unit weighs 9,980 pounds and comes pre-assembled on a standard trailer. You hook it to a pickup and move it to your next job—no permit to haul it, no disassembly required.

Site Selection and Setup

Before you unhook the trailer, location is everything. Choose a flat, level piece of ground with less than 10% slope, and it must be dry. The firebox lowers via hydraulic rams powered by a 12V system. All four sides of the firebox must make solid contact with bare earth. If the ground isn't level, the air curtain won't function evenly, and you'll get smoke escaping from the sides.

Clearance requirements are non-negotiable. Maintain a minimum of 100 feet in all directions from the unit. The firebox operates at 2,400°F—radiant heat extends well beyond the air curtain. Position the unit at least 250 feet from public roads. Check wind direction continuously during operation. A shift in wind can turn a clean burn into a smoke complaint in seconds.

Setting up the trailer is straightforward. Park on level ground, engage the parking brake, and stabilize the trailer. Verify the hydraulic rams lower evenly. The firebox should sit flat and flush with the ground.

Fueling and Engine Operation

The BurnBoss runs on ultra-low-sulfur diesel (ULSD) in a 10-gallon tank. The engine is a two-cylinder diesel, Tier 4 compliant. Fuel consumption is roughly 0.56 gallons per hour. That diesel powers the air fan only—no fuel is injected into the fire itself. The combustion comes entirely from the wood waste and the high-temperature air curtain.

Startup and Ignition

Load the firebox to one-third height with small kindling no larger than 4 inches in diameter. Softwood kindling works best: pine, cedar, or similar. Cover the entire bottom of the firebox evenly so the fire starts uniformly. Once the kindling is in place, ignite it.

You have two safe ignition methods:

• Small paper and kindling torch—light it and place it in the firebox center.
• Approximately 3 gallons of diesel with a propane torch to ignite it. Pour the diesel carefully into the center of the kindling, then apply the torch. The diesel ignites quickly and heats the kindling.

NEVER use gasoline to start the fire. Gasoline vapor is explosive in an enclosed firebox. Diesel is much safer because it doesn't vaporize at room temperature.

Once the kindling is burning well, start the diesel engine and activate the air curtain fan. The forced air will intensify the fire immediately. Once the curtain is on and the fire is strong, begin steady loading from the manifold side.

Loading Technique

Always load from the manifold side (right side of the unit). Never load from the back or attempt to push material in from the side.

Never load material above three-quarters of the firebox height. Load in steady, manageable batches. Continuous feeding of 50-pound batches every 30 seconds keeps the curtain stable.

Approved materials include:

Untreated and clean lumber waste

Forest slash, limbs, and branches

Tree stumps (up to reasonable diameter)

Bark, sawdust, and wood chips

Yard waste and green brush

Absolutely prohibited materials:

• Treated or painted wood (contains heavy metals and toxic chemicals)
• Pallets (burn far too hot and unevenly)
• Tires or rubber
• Plastics or PVC
• Grass clippings (release excessive smoke)
• Paper or cardboard
• Heavy oils or petroleum products
• General trash or demolition waste

Contaminated or pressure-treated lumber contains chromated copper arsenate (CCA) or other poisons. When you burn treated wood, those heavy metals enter the ash and can leach into soil. Burning prohibited materials can result in permit revocation and fines.

Safety Zone and Personal Protective Equipment

Maintain a 100-foot minimum safety zone around the operating unit. No people, no equipment, no structures. Operators should wear fire-resistant clothing. Light-colored long sleeves and long pants. Avoid loose synthetic fabrics that melt. Cotton or flame-resistant wear is best.

When removing ash, always wear a respirator rated for fine particulates(N95 or better). Fire extinguishers should be stationed on-site: Class A extinguisher within 75 feet, Class B extinguisher within 50 feet.

Monitor wind continuously during the burn. If wind direction becomes unfavorable, stop loading and allow the material in the firebox to burn down, then shut off the engine.

Shutdown Procedure

When done, stop loading and allow the material in the firebox to burn down naturally. Once the fire has burned to coals and manageable flame, switch off the diesel engine. Never leave an active burn unattended. After the engine is off, allow at least 30 minutes for the firebox to cool before any maintenance.

Ash Disposal

Roughly 2% of the input material becomes ash or biochar. Clean the ash at the start of each burn day through the rear doors. Excavate when ash reaches 3 feet deep —roughly 20 hours of continuous burning. Wear a respirator during removal. Cold ash can be spread on-site as a soil amendment, depending on local regulations.

Pennsylvania Permits and EPA Compliance

PA DEP Requirements

The PA DEP requires that each use of a BurnBoss must be approved in writing before you start burning. Contact PA DEP Air Quality at 717-783-9476 and request written approval. Provide the site location, type and volume of material, expected burn dates, and purpose. Keep the written approval on-site during the burn.

EPA Exemption for Wood Waste

As of April 2024, the federal EPA has issued an exemption from Title V air permitting for wood waste combustion in certain devices, including the BurnBoss. This exemption applies to wood waste only.

Opacity and Emissions Limits

Steady-state opacity must not exceed 10% (measured as a 6-minute average). For the first 30 minutes of startup, opacity is allowed to reach 35%. After that, if you're seeing clouds of black smoke, you're overloading the firebox or burning prohibited materials.

Check with your local municipality for any additional burn restrictions. Pennsylvania's DCNR Bureau of Forestry can also impose restrictions. Call 717-787-2925 to verify there are no statewide restrictions. During periods of poor air quality, statewide burn bans can be enacted. Always call ahead.

Common Operator Mistakes

Overloading Above the Air Curtain

Cramming material higher than three-quarters full causes pieces to fall out and reduces air flow efficiency, resulting in incomplete combustion and smoke.

Burning Prohibited Materials

A single pallet, treated lumber, or plastic wrap will spike emissions. Pre-separate material before loading.

Burning in Rain, Fog, or High Wind

Rain and fog make smoke appear denser. High wind can push smoke toward populated areas instantly. Wait for clear, calm conditions.

Letting Ash Exceed 3 Feet Deep

Neglecting ash removal reduces firebox volume and hampers air flow. Clean it regularly.

Weather Considerations

Clear, dry conditions are optimal. Never burn during:

• Active burn bans declared by PA DEP or your local municipality
• Rain or wet conditions
• Heavy fog
• High wind
• Nighttime hours

Monitor wind direction continuously throughout the burn day. Have an exit strategy: if wind turns toward a road or neighborhood, shut down and wait for conditions to improve.

Summary and Next Steps

• Site selection is critical: flat ground, 100-foot clearance, 250 feet from roads, level dirt foundation.
• Startup requires careful kindling. Use diesel or paper—never gasoline.
• Load steadily from the manifold side. Never exceed three-quarters height.
• Stick to approved materials: untreated wood waste, slash, stumps, bark, chips. No treated wood, pallets, tires, or plastics.
• PA DEP requires written approval before each burn. Call 717-783-9476. Check for bans via DCNR at 717-787-2925.
• Maintain 100-foot safety zone. Wear fire-resistant clothing and respirator during ash removal.
• Clean ash when it reaches 3 feet deep.