Yes, sandwich panels can be used for both walls and floors in a campervan. The key is matching the right panel configuration to each application: wall panels prioritise low weight and a finished surface, while floor panels need higher compressive and bending strength to handle foot traffic and point loads. The sections below work through the practical questions builders ask most often.
What makes sandwich panels suitable for structural campervan use?
Sandwich panels are suitable for campervan construction because they combine high stiffness with low weight in a single structural element. A composite sandwich panel replaces both the structural layer and the interior finish in one component, removing the need for separate framing, insulation, and cladding. This makes them a practical choice wherever weight and build complexity matter.
The structural logic behind a sandwich panel is straightforward. Two stiff, thin skins are bonded to a lightweight core. The skins carry tensile and compressive loads, while the core resists shear and keeps the skins separated, which is what gives the panel its bending stiffness. The result is a panel that behaves far stiffer than either material would on its own, at a fraction of the weight of solid timber or steel.
For campervan sandwich panel construction applications specifically, this matters because every kilogram saved in the body structure is a kilogram available for equipment, water, batteries, or payload. In 2026, this weight argument has also become a range argument for electric campervans and van conversions: lighter body panels extend battery range per charge, which is increasingly a specification requirement for buyers of electric base vehicles.
Glass-fibre reinforced thermoplastic skins add impact resistance and dimensional stability across temperature cycles, both of which are relevant in a vehicle that moves between climates and sits in direct sun. Unlike timber, thermoplastic composite panels do not absorb moisture, rot, or delaminate when exposed to condensation over time.
Can the same panel type be used for both walls and floors?
No, the same panel type should not be used for both walls and floors in a campervan. Wall panels and floor panels are engineered for different load conditions, and using a wall panel as a floor will result in inadequate compressive and bending performance under foot traffic and point loads. Each application requires a panel configured for its specific demands.
Wall panels: optimised for surface finish and low weight
Wall panels typically use a PP-foam core at lower density, paired with cross-ply glass-fibre skins and a white PET-film surface finish. The cross-ply architecture distributes mechanical properties equally in both directions, which means the panel performs consistently regardless of which way it is oriented during installation. The PET-film surface provides a ready-to-use decorative finish with controlled colour properties and strong UV resistance, removing the need for additional lining or painting.
Floor panels: optimised for load-bearing performance
Floor panels use a PP-honeycomb core, which delivers substantially higher bending and compressive performance than foam cores of comparable thickness. Based on Compoform’s own test data, a 30mm floor panel sustains an average maximum load of 5,647 N in the tested geometry, compared to 3,240 N for a 15mm floor variant. Floor panels also carry a black anti-skid surface finish as standard, which is inherent to this product line and directly relevant for safe movement inside a campervan.
The trade-off is weight: PP-honeycomb floor panels are heavier than wall panels of similar thickness. For a campervan build, this is an acceptable trade-off because the floor represents a small proportion of total panel area, and the structural requirement there is non-negotiable.
What thickness and core density do campervan floors need?
For campervan floor applications, a 30mm PP-honeycomb panel at 140 kg/m³ core density is the appropriate starting point for spans that need to be self-supporting without a subframe beneath. Thinner panels, such as a 15mm variant, are suitable where the floor is fully supported by a close-spaced frame, but they carry a lower maximum load capacity and should be specified carefully against the actual load geometry.
The choice between 15mm and 30mm comes down to two factors: the span between support points and the point loads the floor will see. A 30mm panel can span greater distances without deflection and handles concentrated loads from furniture legs, water tanks, and occupant movement more reliably. Where the floor sits directly on a continuous subframe, a thinner panel may be sufficient, but this needs to be confirmed against the specific load case rather than assumed.
Core density also affects performance. PP-foam cores are available across a range of densities, and higher density grades increase both stiffness and compressive strength. For floor applications, the PP-honeycomb core at 140 kg/m³ is the standard choice because it delivers the highest load performance in the product range. Custom foam-core configurations using higher-density PP-foam grades are also possible for applications where the load profile sits between a standard wall panel and a full honeycomb floor panel.
How are sandwich panels fixed to campervan walls and floor frames?
Sandwich panels in campervan construction are typically fixed using mechanical fasteners through the skins into a perimeter frame, or bonded using structural adhesive along the panel edges and at intermediate support points. The fixing method depends on whether the panel is removable, the substrate material, and the load direction the joint needs to resist.
For wall panels, bonding with structural adhesive is common because it distributes load evenly across the skin surface and avoids point stress concentrations. Where panels need to be removable for maintenance access, mechanical fixing with screws or rivets through a perimeter extrusion is the practical alternative. In both cases, the fixing should engage the skin, not just the core, since the core material is not designed to carry fastener pull-out loads on its own.
Floor panels are more commonly mechanically fixed because they experience higher loads and may need replacement over the vehicle’s life. Screws or bolts through the panel into the floor frame are standard, with load-spreading washers used where point loads are high. Edge protection is worth considering for floor panels in a campervan: sealed or banded edges prevent moisture from entering the core at cut edges, which is relevant in a space where water spillage and condensation are routine.
Panel dimensions up to 13,500mm x 2,950mm are achievable in a single piece, which means campervan walls and floors can often be produced as single panels without joins. Eliminating mid-span joints simplifies installation and removes potential weak points in the structure.
How do sandwich panels handle moisture and temperature in a campervan?
Thermoplastic sandwich panels handle moisture and temperature variation well in campervan environments. PP-foam and PP-honeycomb cores do not absorb water, and glass-fibre reinforced thermoplastic skins are inherently moisture-resistant. This makes them significantly more durable than plywood in a space where condensation, cleaning water, and humidity cycling are routine.
Temperature performance is relevant in a campervan because the interior can swing from below freezing on a winter night to well above 40°C in direct summer sun. Thermoplastic composite panels expand and contract with temperature, but the coefficients involved are manageable with standard fixing details that allow for movement. Unlike timber, thermoplastic panels do not warp, swell, or delaminate as a result of moisture absorption combined with temperature change.
The white PET-film surface on wall panels carries over 22,000 hours of UV resistance based on Compoform’s technical data, which is relevant for panels near windows or in roof applications where indirect UV exposure is ongoing. The anti-skid surface on floor panels is similarly durable and does not degrade with regular cleaning.
One practical point worth noting: cut edges expose the core material and should be sealed or banded, particularly on floor panels in a campervan where water contact is more likely. Edge sealing is a straightforward step during fabrication and protects the panel’s long-term performance in a humid environment.
What’s the difference between thermoplastic and aluminium-faced sandwich panels for campervans?
The main difference between thermoplastic and aluminium-faced sandwich panels for campervans is in impact behaviour, repairability, and long-term durability. Thermoplastic composite panels absorb impact energy without permanent deformation at lower impact levels, and they can be thermoformed or repaired. Aluminium-faced panels are lighter per unit area in some configurations but dent permanently under impact and are more difficult to repair in the field.
Aluminium-faced panels have historically been common in caravan and campervan construction because aluminium skins are thin, light, and provide a clean exterior surface. However, aluminium is prone to galvanic corrosion where it contacts dissimilar metals, and dents from road debris or handling are permanent. In a vehicle that sees regular use over many years, this becomes a maintenance and appearance issue.
Thermoplastic composite skins, particularly glass-fibre reinforced PP, offer higher impact resistance. Compoform’s continuous fibre-reinforced tape technology delivers 50% higher impact resistance compared to standard composite materials, based on the company’s own development work. This is a meaningful difference in a campervan context where the body panels are exposed to road stone impact, loading and unloading, and general handling.
From a sustainability standpoint, thermoplastic panels are fully recyclable at end of life, which is relevant for European manufacturers subject to EU End-of-Life Vehicle (ELV) Directive requirements. Aluminium is also recyclable, but the adhesive systems used to bond aluminium skins to foam cores can complicate separation and recycling. Thermoplastic panels bonded with compatible thermoplastic adhesives are easier to process as a single material stream.
How We Help with Sandwich Panel Selection for Campervans
At Compoform, we work with vehicle builders and converters to specify the right panel configuration for each surface in the build, rather than applying a single panel type across the whole vehicle. For campervan projects, this typically means:
- Wall panels: We review the span, fixing method, and surface finish requirement, then recommend the appropriate thickness and skin architecture from our PP-foam core range.
- Floor panels: We assess the load geometry, support spacing, and expected point loads, then specify the correct PP-honeycomb panel thickness and confirm whether edge sealing or banding is needed for the application.
- Custom dimensions: Panels are produced to your exact dimensions, up to 13,500mm x 2,950mm, which means walls and floors can often be cut as single pieces without mid-span joins.
- Core and skin configuration: Where standard configurations do not match the load case, we can adjust core density, skin ply count, or layer orientation to hit the structural target without adding unnecessary weight.
We review your design before production, flag any integration issues, and support you through the first installation. If the load case or fixing detail changes during the build, we work through the revised specification with you rather than leaving you to resolve it alone.
If you are specifying sandwich panels for a campervan or van conversion project and want to confirm the right configuration for your walls and floor, contact our engineering team with your panel dimensions, load requirements, and fixing method. We will review the application and recommend a panel specification matched to your build.