The Material Decision That Affects Your Fleet for Years

When it comes to custom truck bodies, one of the most important decisions you’ll make is choosing between aluminium and steel construction. Both materials have proven track records across Australian fleets, but they suit different operations. At VN Truck Bodies, we build in both — and here’s how to decide which is right for you.

Aluminium: Lightweight Strength

Aluminium bodies weigh significantly less than equivalent steel builds — typically 30–40% lighter. For operators who are payload-sensitive (refrigerated freight, retail delivery, or long-haul runs), that weight saving translates directly into more cargo capacity per trip, lower fuel consumption, and reduced tyre wear over the vehicle’s life.

Aluminium is also naturally corrosion-resistant. It won’t rust, which makes it ideal for food-grade transport, coastal routes, or any operation where the body is regularly washed down. Maintenance costs over a 10-year period are generally lower for aluminium bodies for this reason alone.

The trade-off is cost: aluminium fabrication is more expensive upfront, and while it handles everyday loads well, it can dent more visibly than steel under impact.

Steel: Durability Under Pressure

Steel remains the default choice for heavy-duty applications — tray bodies for construction sites, drop-sides carrying machinery, or any operation where the body takes hard knocks daily. Steel bodies absorb impact better, can be repaired and re-welded on-site in many cases, and are more forgiving in harsh environments.

The downside is weight and corrosion. Steel bodies need regular inspection for rust, particularly around mounting points, door frames, and the underside. Proper protective coatings at build time are essential, and periodic touch-ups extend body life significantly.

Galvanised Steel: The Middle Ground

For operators who want steel strength with better corrosion protection, galvanised or Zincalume steel is a popular option. It costs more than plain steel but significantly less than aluminium, and provides meaningful rust resistance for bodies operating in wet or coastal environments.

Which Is Right for Your Fleet?

If you’re running refrigerated vans, light commercial deliveries, or vehicles where payload maximisation matters — aluminium is worth the investment. If you’re running tray bodies, crane trucks, tipper backs, or heavy-duty transport — steel gives you the robustness you need.

Not sure? The team at VN Truck Bodies can walk you through both options based on your GVM, payload requirements, and operating conditions. Call us on 03 9798 2573 or visit us at 17 Cambria Road, Keysborough.