Special vehicle bodies

Specialised laminate vehicle bodies are a key element of infrastructure in many industries, from emergency services to the food and pharmaceutical industries. The use of composite materials makes it possible to create structures adapted to the most demanding operating conditions. Polyester-glass and epoxy laminates provide high mechanical, chemical and thermal resistance, which translates into longevity and functionality of the finished structure. The modern market demands durable yet lightweight structures, which is why composites have become the foundation for building modern car bodies.

A comprehensive approach to vehicle conversion requires precise adaptation of technology to the nature of the vehicle and the specific characteristics of the industry. Thanks to the use of modern moulds and thermoforming technology, it is possible to obtain ergonomic, hygienic and easy-to-maintain bodies that meet strict performance standards. A properly designed composite structure guarantees not only strength, but also aesthetics and functionality.

 

Advantages of laminate bodies for special vehicles

Special bodies made of laminate are distinguished by their exceptional resistance to weather conditions, impacts and chemicals. Compared to traditional materials such as steel or aluminium, laminates offer lower weight, which translates into lower fuel consumption and increased vehicle load capacity. Composites also offer excellent thermal insulation, which is invaluable in vehicles transporting products that require temperature control.

An additional advantage of laminates is the possibility of precisely matching shapes and creating structures with complex geometry. The absence of joints and gaps reduces the risk of dirt accumulation, which is particularly important in sectors with high sanitary requirements. The laminate manufacturer develops materials according to the individual needs of the user. This allows each installation to be optimised in terms of functionality, which significantly reduces installation time and facilitates servicing.

 

Designing laminate special vehicle bodies

The process of designing special laminate bodies begins with an analysis of the specific nature of the vehicle's operation. It is crucial to precisely define technical parameters and functional requirements, such as resistance to temperature, chemical agents or mechanical damage. The design documentation is developed on this basis, taking into account both ergonomics and technological aspects.

An important element of the design is the selection of the type of composite – depending on the intended use, different types of laminates are used, including epoxy or polyester resins reinforced with glass fibre. This makes it possible to create structures with specific functional properties. Modern designs also use CAD/CAM systems, which enable precise reproduction of details and full control over the production process.

 

Application of laminate special vehicle bodies

Laminate special vehicle bodies are widely used in many sectors of the economy. They are perfect for refrigerated vehicles, mobile laboratories, ambulances, service units and technical containers. Thanks to the properties of composites, it is possible to obtain structures with a high degree of hygiene, making them ideal for transporting food, medicines or biological materials.

This type of structure is also used in the military and energy industries, where resistance to extreme external conditions is important. Their light weight and high structural rigidity enable easy installation on various chassis. 

 

Structural integration of the body with the chassis

Correct and secure connection of the bodywork to the vehicle frame is a key design aspect. Our design process includes precise modelling of the intermediate frame and mounting points, which ensure optimal transfer of static and dynamic loads. We analyse weight distribution, chassis torsional stiffness and suspension characteristics to design flexible or rigid connections depending on the type of vehicle and its intended use. The use of appropriate adapters and fasteners made of high-strength materials ensures that special vehicle bodies will form an integral and reliable part of the entire structure, capable of operating in the most difficult road and off-road conditions.

 

Isothermal structures in special vehicle bodies

In refrigerated and pharmaceutical transport, maintaining a stable temperature is crucial. Our isothermal bodies are constructed using sandwich panel technology. The insulating core, made of rigid polyurethane (PU) foam or extruded polystyrene (XPS) with a low thermal conductivity coefficient, is covered on both sides with layers of laminate. This structure not only provides excellent insulation, but also high rigidity with low weight. We place particular emphasis on eliminating thermal bridges by using special composite profiles and multi-stage door sealing systems. This ensures that our bodies meet the requirements of the ATP agreement, allowing them to be certified for the transport of perishable goods.

 

Fire safety

In many sectors, such as public transport, railways and the military, construction materials must meet stringent fire safety standards. We manufacture special vehicle bodies using specialised, fire-retardant resin systems and flame retardants (antipyrenes). These components are characterised by low smoke emission and toxicity, as well as self-extinguishing properties. Depending on customer requirements, we are able to supply laminates that meet specific flammability classes according to European (e.g. EN 45545 for railways) or international standards. This not only ensures safety, but also ensures that the vehicle complies with the regulations applicable in the industry.

 

Maximum load capacity and efficiency of special vehicles

Every kilogramme of the vehicle's own weight is one kilogramme less potential load capacity. That is why weight optimisation is an important part of our engineering process. We employ advanced design methods, including finite element analysis (FEM), to identify low-stress areas and reduce laminate thickness without compromising strength. We also use lightweight core materials in the sandwich structure and, where necessary, high-strength carbon fibre reinforcement in key areas. The result is one of the lightest and most durable bodyworks on the market, which directly translates into increased load capacity, reduced fuel consumption and improved vehicle operational efficiency.

 

Special vehicle bodies in the form of kits

We understand the needs of body shops and vehicle manufacturers, for whom time is a critical resource. That is why we offer our special vehicle bodies not only as ready-made units, but also in the form of precisely prepared assembly kits. Such a kit may contain all the necessary elements: wall and roof panels, prefabricated flooring with a non-slip layer, internal partition walls, as well as reinforcements for the installation of generators or other equipment. All components are precisely cut on CNC machines and prepared for quick and easy assembly, which significantly reduces the time needed for final vehicle assembly at the customer's premises.