Would you have a box van made from composite cardboard panels skinned with a High Pressure Laminate (HPL)? It sounds lightweight, technologically advanced and eco-friendly — yet would it hold up to the rigours of use? Would it withstand decades of expected abuse and remain waterproof and looking great? Would you have to spend heavily on repairs? These are exactly the questions every fleet specialist should be asking — and exactly why we introduced Blade panels.
Since its introduction in 2008, Don-Bur’s proprietary Blade bodywork system has become the benchmark for box van durability and performance — now used on more than 90% of all box van bodywork manufactured by the company.
The industry’s long-standing default — GRP-faced plywood — may appear robust, but once moisture penetrates the GRP skin, the plywood core can quickly delaminate, swell and rot. Blade was developed as a direct response to this issue: a precision-engineered composite that resists damage, moisture and corrosion while maintaining its integrity year after year.
Every panel has a purpose, and Blade’s purpose is simple — to deliver uncompromising quality and dependability in one of the most demanding environments on the road.
A Composite Built for a Purpose
Each Blade panel is a precision-engineered composite of galvanised steel skins bonded to an HDPE foam core, finished with a polyester baked-on paint coating that provides an ideal surface for body colour finishes. Beneath the paint lies a rust-inhibiting primer and hot-dip zinc layer applied to 80,000-psi yield full-hard steel — forming a robust barrier against corrosion and external wear.
The result is a panel that is slim, strong and extremely impact resistant. Unlike GRP-faced plywood, Blade panels will not absorb moisture, delaminate or deteriorate — even under long-term stress, exposure or vibration. Fleets have proven this over more than a decade of continuous service, with Blade-bodied trailers maintaining their appearance and structural integrity far beyond typical fleet life cycles.
The Key to Its Success
- Extreme durability: Steel skins and a fully bonded core resist impact, flex and vibration damage in high-usage environments.
- Corrosion resistance: Hot-dip zinc coatings and sealed bonding prevent rust and moisture ingress.
- Service longevity: Panels retain rigidity and appearance over extended operational life, reducing downtime and repair frequency.
- Recyclable construction: Both steel and HDPE can be fully reprocessed, supporting circular-economy principles.
- Professional appearance: Smooth, paint-ready surface finish provides consistent quality across the fleet.
Increased Pallet Capacity on Lifting Deck Trailers
Blade’s design precision delivers practical engineering advantages — particularly in lifting deck trailers, where internal width is at a premium. The panel’s reduced 7.5 mm thickness allows Don-Bur engineers to widen the upper deck cradle, achieving a full 2.44 m clear width between the upper deck sides. This creates ample clearance for two standard UK pallets positioned with their longest sides across the trailer width.
The result is a true 52-pallet capacity — double that of an equivalent single-deck trailer — achieved without compromising durability or service life. It’s a perfect example of how engineering refinement translates directly into operational efficiency.
ESG and Sustainability Benefits
Durability isn’t just a practical advantage — it’s an environmental one. Blade’s exceptional service life reduces the need for replacements, cutting material consumption and embodied emissions. At end-of-life, both the steel and HDPE components can be recycled, ensuring the system supports modern sustainability goals.
- Lower lifecycle impact: Extended durability reduces replacement frequency and associated emissions.
- Recyclable materials: All core components can be reprocessed within standard recycling streams.
- Reduced waste: Long-term integrity eliminates early disposal caused by delamination or rot.
Repairs In Practice
The images attached show localised impact damage to the upper offside corner of a Blade-bodied trailer. In this case, only a single panel section requires replacement — highlighting the practicality and maintainability of the system. With standard GRP-faced plywood, repairing this sort of damage would typically require removing and replacing the entire side panel — a large, labour-intensive task. By contrast, with Blade only the damaged section needs replacing, saving both time and cost. However, while repairability is a welcome benefit, the real strength of Blade lies in its resilience: impacts like this are rare relative to the total service life of the bodywork.
For full technical detail, see the Blade feature page and the Panel Specification Comparison Chart.
Today, Blade remains Don-Bur’s benchmark body panel — proven, reliable, and aligned with the quality, environmental and operational goals of the modern transport industry.
