A proven composite system for UK box-van bodywork, engineered for strength, dimensional stability and long-term resilience.
Exclusive to Don-Bur, Blade panels are slim, strong and exceptionally durable. Their 7.5 mm profile increases internal width, supporting improved cubic capacity for high-volume operations while maintaining robust structural performance.
Each Blade panel is a precision composite made from a high-density HDPE (High-Density Polyethylene) core bonded between full-hard galvanised steel skins. A polyester baked-on coating provides consistent colour adhesion and weather protection.
Constructed entirely from recyclable materials, Blade supports circular-economy objectives and aligns with modern sustainability requirements.
Performance Characteristics
Impact behaviour and abrasion resistance. Blade's steel-HDPE composite structure distributes impact loads through the skins and core, reducing the risk of cracking, splintering or substrate damage during loading operations. The steel faces deform predictably under stress, helping maintain overall panel integrity in day-to-day use.
Moisture and chemical resistance. The sealed HDPE core is non-absorbent and highly resistant to water, salts and common cleaning chemicals. This prevents rot, swelling and delamination and helps maintain durability in wet, coastal or corrosive environments.
Dimensional stability and flatness. Bonded steel skins combined with a rigid HDPE core provide stable panel geometry across temperature cycles. The design minimises thermal-induced distortion and supports clean paint lines and consistent branding surfaces.
Superior mechanical fixing performance. The composite structure provides a reliable substrate for load-restraint installations such as Load-Lok tracking. Mechanical fixings benefit from predictable pull-out resistance due to the stiffness of the steel skins and the stabilising core.
Improved edge and aperture integrity. HDPE cores maintain clean edges when cut, allowing stable integration of door frames, apertures and ancillary components without moisture tracking or substrate breakdown.
Operational Benefits
Blade panels do not splinter or gouge like GRP-faced plywood, and they resist dents and corrosion. Their performance characteristics reduce lifetime repair requirements and help maintain vehicle appearance over extended service periods.
Don-Bur's post-and-panel construction also means that any damaged Blade section can be replaced independently, avoiding the cost and downtime associated with replacing full GRP panels.
Compare Blade against other panel systems in the Panel Specification Chart, or explore real-world installations in the product gallery below.
More than 90 % of Don-Bur customers now specify Blade bodywork on both new builds and repeat orders, demonstrating continued confidence in its durability and long-term value.
FAQs
What are Blade panels made from?
Blade panels use a recyclable HDPE foam core bonded between galvanised steel skins with a baked-on polyester finish, providing strength, durability and a stable outer surface.
Do Blade panels absorb water?
No. The HDPE core is fully sealed and non-absorbent, preventing moisture ingress, rot, delamination or swelling over time.
Are Blade panels resistant to chemical and road salt exposure?
Yes. HDPE has excellent chemical resistance, making Blade suitable for coastal environments, winter road conditions and routine cleaning operations.
Can a single damaged panel be replaced?
Yes. The post-and-panel system allows individual Blade sections to be removed and replaced without disturbing adjacent panels.
Are Blade panels suitable for installing load-restraint fixings?
Yes. The rigid composite structure provides predictable pull-out resistance, making it suitable for tracking systems and other mechanically fixed components.
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