Composite Construction

Why Choose Composite Construction?

Stronger, Lighter, and Built to Last

Caravans built using composite panels offer a range of important benefits over traditional timber-framed models. Unlike timber, composite materials don’t rot, decay, or attract insects, meaning your caravan keeps its strength and structure for many years to come.

Composite panels are significantly lighter than traditional materials, making caravans easier to tow, more fuel-efficient, and less taxing on your vehicle. This results in a smoother, safer, and more efficient journey—perfect for long road trips and off-road adventures.

These panels also provide excellent thermal insulation. When the Aussie sun is beating down, your caravan stays cooler for longer, helping you achieve a comfortable interior temperature more quickly and with less energy use.

In addition to temperature control, composite construction offers superior noise insulation. It helps keep interior noise contained while blocking out unwanted sounds from outside, creating a quiet and peaceful environment inside your van—wherever your travels take you.

What Are Composite Panels?

Composite construction replaces traditional wooden or metal frames with high-performance panels known as sandwich panels. These panels are made by bonding a strong, lightweight foam core between two tough outer layers—often fiberglass. The result? A frameless structure that’s incredibly strong, weather-resistant, and thermally insulated.

Unlike older materials like meranti, plywood, or aluminium, composite panels are completely rot-free and far better suited to Australia’s tough conditions. Their lighter weight also means more room for gear and a more enjoyable travel experience.

Introducing Aeroglass

At Grand Caravans, we’ve taken composite construction even further with Aeroglass—our exclusive range of custom-engineered caravan panels. Using cutting-edge techniques and materials, Aeroglass delivers exceptional strength, insulation, and long-term durability for both roofs and walls.

Already setting a new standard in the industry, Aeroglass Caravans are fast becoming the preferred choice for savvy travellers. With more manufacturers expected to adopt this technology, Aeroglass is proudly leading the way in the future of caravan construction.

At Grand Caravans, we use premium Aeroglass composite panels in our caravan construction. Each panel is made up of three high-quality layers designed for strength, durability, and performance. We use 1.6mm fibreglass with a 25mm XPS core for the side and back walls, and 1.6mm fibreglass with a 35mm XPS core for the front wall and roof.

The outer layers are crafted from GRP (Glass Reinforced Polyester) fibreglass, known for its toughness, impact resistance, and long-lasting finish. Sandwiched between them is a structural XPS (eXtruded PolyStyrene) foam core—a closed-cell, high-strength material that offers outstanding insulation and rigidity.

Our XPS foam is rated at 400 kPa, delivering greater structural integrity than the standard XPS used by many other manufacturers. This means your caravan is not only lighter and more efficient, but also stronger and better equipped for the demands of Australian conditions. XPS is a closed-cell foam, it will not absorb water, ensuring your caravan remains rot-free, lightweight, and well insulated—no matter the conditions.

Aeroglass composite construction is a key innovation that sets Grand Caravans apart. By combining advanced materials with superior engineering, we’ve created a product that is lighter, stronger, and more durable—perfectly suited to Australia’s tough and varied landscapes. Whether you’re heading off-road or embarking on long-distance travel, our Aeroglass panels provide the confidence, comfort, and reliability you need for every journey. It’s not just a better way to build caravans—it’s the future of caravan construction.