Steel is a core material in the manufacture of our commercial vehicle trailers and rigid bodywork. It forms the structural foundation of the chassis and supports a wide range of load-bearing and protective components.
Its performance, however, depends on how it is specified, processed and protected. The choices we make around grades, formats, fabrication methods and surface treatments directly influence durability, safety and long-term operational performance.
Why Steel Still Leads the Way
- High strength-to-weight performance
- Consistent and predictable fabrication — suitable for cutting, forming and welding
- Established and reliable supply chains
- Long service life, particularly when corrosion protection is applied correctly
Grades and Forms We Use
We work with a range of structural steel grades, including (but not limited to) S235, S275, and S355, selected based on their mechanical properties and application requirements. All materials comply with relevant UK and EU standards.
Steel is primarily supplied in sheet form, offering flexibility across both chassis and bodywork applications. Where required, we also use box section and tube section steels for structural and load-bearing elements. Smaller components may incorporate pre-galvanised pressings, providing corrosion resistance from the outset.
In-House Fabrication Capabilities
- Large fibre laser cutting for precise profiles with minimal waste
- Beam welding machines to achieve consistent, high-strength welds on main chassis rails
- Robotic welding systems for repeatable accuracy on complex components such as bed plates
Maintaining these processes in-house allows us to control dimensional accuracy, weld quality and overall structural integrity at every stage of manufacture.
Why We Spray Galvanise Our Chassis
For large welded chassis structures, hot-dip galvanising introduces several risks. Immersing assemblies in molten zinc can result in:
- Distortion caused by thermal shock
- Micro-cracking within welds and heat-affected zones
- Inconsistent coating thickness across complex geometries
In addition, post-fabrication rework on galvanised steel presents health and safety concerns. Heating the coating during welding or cutting can release zinc oxide fumes, requiring specialist controls such as extraction, PPE and hot-work permits.
Instead, where required, we apply zinc spray galvanising (zinc metallising) after fabrication. This approach provides:
- Uniform coverage, including welds and joints
- No thermal distortion of the structure
- A textured surface that improves primer adhesion
- Simpler and safer maintenance or localised repair
- Reduced need for secondary rework
Engineering for Lightweight Durability
While steel delivers structural strength, unladen weight remains a key consideration. Payload efficiency is particularly important in weight-sensitive operations.
Our engineering approach focuses on optimising material use without compromising safety or durability. Techniques include:
- Finite Stress Analysis (FEA) to identify and remove excess material
- Application-specific design for sectors such as aggregate transport and the brewing industry
- Targeted reinforcement only where structurally required
In some applications, we also make selective use of higher-strength steels (often referred to as "supersteel"), for example in structures such as meganeck assemblies, where weight reduction can be achieved without increasing section size. However, using thinner, higher-strength sections introduces different structural behaviour, particularly increased flex, so these materials are applied carefully and only where the design can accommodate it.
Where appropriate, we also assess alternative materials such as aluminium, composites and GRP panels. These can reduce weight further but involve trade-offs in cost, durability and repairability, so are used selectively based on operational requirements.
Responsible Sourcing and Sustainability
Steel is sourced from approved suppliers with full traceability and compliance with recognised quality standards.
From a sustainability perspective, steel remains a practical material choice. It is fully recyclable, and many products already contain recycled content. Manufacturing offcuts and scrap are segregated and returned to the recycling stream to minimise waste.
Final Thoughts
The performance of steel components is defined by how they are specified, processed and protected. Through controlled sourcing, in-house fabrication and application-specific engineering, we ensure each component is suited to the demands of commercial vehicle operation.
Market Factors Affecting Steel Costs
Steel pricing is influenced not only by material specification and processing, but also by wider regulatory and market conditions.
From 2026, two key developments are expected to affect cost structures across the UK commercial vehicle sector:
- Steel tariff-rate quotas (TRQs) taking effect from July, which may restrict import volumes and apply additional duties where quotas are exceeded
- Carbon-related cost mechanisms being introduced from January, increasing the cost base of energy-intensive materials such as steel
These factors have the potential to increase input costs and introduce greater volatility in steel pricing. As a result, material selection, structural efficiency and procurement strategy become even more critical.
Our approach remains focused on engineering efficiency, controlled sourcing and application-specific design to ensure that any cost pressures are managed without compromising structural performance or durability.
