Steel plays a critical role in the manufacture of our commercial vehicle trailers and rigid bodywork. From the chassis beneath to the protective elements on top, it delivers the strength, versatility, and reliability that our customers depend on every day.
But steel isn't just steel — and the choices we make about grades, formats, fabrication and surface treatments have a big impact on long-term durability, safety and performance. Here’s how we approach it.
Why Steel Still Leads the Way
- Excellent strength-to-weight balance
- Predictable fabrication characteristics — easy to cut, fold and weld
- Reliable supply and pricing stability
- Superior longevity, especially when properly protected against corrosion
Grades and Forms We Use
We work with a range of structural steel grades, including (but not limited to) S235, S275, and S355, each selected for its mechanical characteristics and suitability for the task at hand. All comply with UK and EU standards.
Most of our material is procured in sheet form, which gives us flexibility across various bodywork and chassis applications. However, we also use box section and tube section steel where appropriate, particularly in structural and load-bearing areas. In addition, we incorporate pre-galvanised pressings for smaller components that benefit from corrosion protection straight from the mill.
In-House Fabrication Capabilities
- Large fibre laser for high-precision cutting with minimal waste
- Beam welding machines for strong, consistent welds on main chassis rails
- Robotic welders for intricate, repeatable welds on complex components like bed plates
This approach ensures every structural component is manufactured to spec — with the strength and durability that heavy-duty commercial transport demands.
Why We Spray Galvanise Our Chassis
For large steel chassis, hot-dip galvanising can be problematic. Although it's sometimes used in other industries, submerging large welded structures into molten zinc introduces serious risks:
- Distortion due to thermal shock
- Micro-cracking in welds and heat-affected zones
- Uneven coating, especially in complex assemblies
But perhaps even more critically, any rework on hot-dip galvanised steel — such as drilling or welding — poses health and safety risks. Heating galvanised coatings can release toxic zinc oxide fumes, requiring full PPE, extraction systems and hot-work permits. It adds time, cost, and complexity.
Instead, where required, we apply zinc spray galvanising (zinc metallising) after fabrication. This gives us:
- Complete coverage, including welds and joints
- No risk of structural distortion
- A coarse surface that promotes primer adhesion
- Safer and simpler maintenance if touch-ups are ever required
- Minimal need for post-treatment rework
Engineering for Lightweight Durability
While steel provides excellent structural performance, we understand that unladen weight matters, especially for industries where payload efficiency is critical.
Our engineering team focuses heavily on lightweighting techniques, using smart design to reduce unnecessary mass without compromising strength or safety. This includes:
- Finite Stress Analysis (FEA) to optimise material usage and remove excess steel
- Tailored designs for weight-sensitive sectors such as aggregate transport and the brewing industry
- Strategic use of reinforcements only where necessary
Where required, we also explore high-tech lightweight alternatives to steel — such as aluminium, composites, or GRP panels — particularly in bodywork components. While these materials can offer further weight savings, they come with trade-offs in terms of cost, durability, and repairability, and are therefore used selectively where the application justifies the investment.
Responsible Sourcing and Sustainability
We procure our steel from trusted suppliers who provide full traceability and comply with stringent quality standards.
Steel also aligns with our sustainability goals — it’s 100% recyclable, and many of the steels we use already contain recycled content. Any offcuts or scrap produced during manufacturing are recycled responsibly to minimise waste.
Final Thoughts
Steel might be a basic material on the surface, but in our world, it’s anything but. From grade selection and structural design through to precision fabrication and corrosion protection, it underpins every trailer and rigid body we manufacture.
By combining robust sourcing with smart engineering, controlled in-house processes, and strategic lightweighting, we ensure that every steel component we build is ready for the long haul.
