Corrugated Aluminium vs Composite Sheets: Cladding Comparison For Timber-Frame Caravans

Choosing the right exterior cladding is one of the most overlooked decisions people make when ordering a new caravan. It shapes not only the look of your van, but also its weight, durability, and long-term maintenance needs.

At Adelaide RV, we offer two proven options across our Supreme and Leader timber-frame vans: traditional corrugated aluminium and flat composite sheet panels. Both are tried-and-tested, workshop-approved and backed by years of real-world touring across corrugations, coastlines and outback tracks.

In this cladding comparison, we break down the key differences – so you can choose with confidence.

Why Timber-Frame Construction Matters First

Before we compare the external skins, it’s worth touching on why cladding performs differently on a timber frame.

A caravan in motion doesn’t behave like a solid box. If you’ve ever mounted a GoPro inside your van while travelling, you’ll see: everything flexes. A timber frame naturally absorbs this twist and movement, especially on corrugated roads.

This flexibility prevents the external skin from tearing away or placing stress on the joins, which can happen with more rigid frames or one-piece sandwich-panel walls.

Both cladding types we offer are designed to work with this flexibility – just in different ways.

1. Corrugated Aluminium Cladding

✔ Significantly lighter

Weight is one of the biggest advantages of corrugated aluminium.
It’s around 11kg lighter per linear metre than composite sheeting.
On a 21’6″ van, that’s roughly 70kg saved – the equivalent of:

• Two cartons of beer

• Almost a full tank of fresh water

• Extra tools, toys or recovery gear

For families towing with a mid-size 4WD or anyone running close to their GCM, this is a meaningful advantage.

✔ More forgiving to dents and travel wear

Flat panels show imperfections. Corrugations do not.
If you get a superficial dent, the sun and shadows disguise it naturally. It’s a practical option if you’re touring rural areas, squeezing into tight tracks or parking around kids, bikes and gear.

✔ Easier and quicker to repair

Each sheet is only 300mm high, meaning if one section is damaged, we can replace just that strip after removing the panels above – no need to remove a full wall. This keeps repair costs and downtime to a minimum.

✔ Perfectly suited to timber-frame flexibility

This cladding is stapled to the timber frame and works with it, rather than against. It stays firmly attached even as the van flexes and twists during travel.

Things to Consider

• Slightly more old-school in appearance

• Fewer colour options

• Not as impact-resistant as composite

• Still uses composite sheeting on the front (where stone damage occurs)

For many travellers, especially weight-conscious tourers, the traditional cladding remains the most practical choice.

2. Composite Sheet Cladding

Composite sheet cladding is a 3mm aluminium–rubber–aluminium sandwich panel. It offers a sleek, modern look many new caravan buyers prefer, and there are other benefits:

✔ Modern aesthetic & broad colour choices

The smooth finish delivers a clean, contemporary look. It also offers a wider range of colours, allowing owners to personalise their van more directly.

✔ More impact resistant

Composite sheeting handles:

• hail

• stone chips

• low-hanging branches

• corrugated-road vibration

This makes it a strong choice for off-road buyers or those storing in hail-prone regions.

✔ Cleaner sealing around windows and fittings

Because the panel is perfectly flat:

• seals compress more evenly

• joins sit tighter

• windows and doors have no visible gaps

This provides cosmetic improvement and keeps everything looking neat long-term.

✔ Purpose-built stress joints for flex

Flat panels cannot flex the way corrugated aluminium can, so we incorporate expansion joints into the composite sheet system at known stress points. These joints prevent stress cracks and allow the panel to move naturally with the timber frame.

Things to Consider

• Heavier – around 11kg per linear metre more than standard corrugated

• More complex to repair – replacing a section requires removing fittings and being more intrusive

• Dents stand out more because the finish is smooth

• Repairs may take longer a little longer – something to remember if you’re living in your van or travelling full-time

Composite is ideal for customers prioritising style, rigidity and hail resistance – provided they’re comfortable with the additional weight.

A Hybrid Approach: The Best of Both Worlds

Even if you choose corrugated sides, every Supreme and Leader still uses composite sheet on the front – the area most likely to cop stone damage. Paired with a high checker plate, this gives you impact protection exactly where you need it.

This means:

• composite on the front and rear

• traditional corrugated aluminium down the sides

• optional full composite sides at no extra cost

Yes – there’s no cost difference whatsoever. The choice is purely yours.

Which Should You Choose?

Pick Corrugated Aluminium if you want:

• maximum weight savings

• the easiest repairs

• a forgiving finish for dents

• a classic caravan aesthetic

• towing efficiency

Pick Composite Sheet if you want:

• a sleek, modern look

• more colour options

• improved hail and stone resistance

• tighter seal lines around windows

• premium styling

Both options perform exceptionally well in Australian conditions when paired with a timber frame. After seven years rebuilding caravans in our workshop, Jono’s advice is simple:

Choose the cladding that best matches how you travel, your towing setup and the look you want.

Final Thoughts 

Your van’s exterior should give you confidence on the road – whether you’re heading up the Oodnadatta, pulling into a family holiday park, or exploring the coastline. At Adelaide RV, we guide you through the process step-by-step, ensuring the cladding you choose complements your adventures, your tow vehicle and your long-term plans.

If you’d like to see both cladding styles side-by-side, visit our dealership in Green Fields. Our team will walk you through the weight differences, repair processes, colour selections and real-world performance – helping you make a decision that feels right for your journey.

Your adventure starts with the right build. We’re here to help every step of the way.