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Why Plastic Material Is Used In Trailer Manufacturing

It takes top-notch materials to construct quality trailers. Since 1968, Piedmont Plastics has only provided the highest-quality products, which is why we introduced our own line of specialty vehicle materials that were made explicitly for critical trailer applications. We recognize the need for reliable and affordable solutions for trailer and toy hauler manufacturers, and we believe our PolyCor products are capable of providing you with the solutions you need for trailer manufacturing.

Why Use Plastic In Manufacturing A Toy Hauler?

A toy hauler can be a travel trailer, fifth wheel, or even a motorhome, and it will have all of its characteristics and additional benefits. A toy hauler is essentially a garage attached to the end of an RV large enough for adult "toys”, such as extra camping gear, small recreational vehicles, motorcycles, and more. It features a big ramp door that makes loading and unloading simple. Many fans of toy haulers like the extra space and the limitless options it provides.

Here are some essential parts used in making toy haulers and how plastics play a prominent role in manufacturing.

Siding Panels

Toy hauler walls and siding are frequently made of aluminum due to their low weight and convenient usage. However, this material has one aesthetic drawback—oil canning. In addition, aluminum sheeting expands over time when exposed to heat and cold, forming a wavy pattern on the trailer's side that can be distracting if the trailer features commercial graphics.

Piedmont Plastic's PolyCor® AP material provides the same advantages as aluminum without the oil canning problem. This specially engineered sheet adds stability to trailer walls and enhances the trailer's appearance. In addition, it has a flat surface and a protective coating that can be easily printed on or painted any custom color when ordering. The end product is a trailer with stronger walls that won't oil can and will have a more pleasing look.


A headliner prevents moisture from leaking through the toy hauler's roof. Traditionally, plywood with a vinyl coating or a fiber-based product, such as coated cardboard, has been used as headliner materials. Unfortunately, these conventional products aren't entirely waterproof; sometimes, getting wet can completely ruin them. Piedmont offers a truly water-resistant headliner plastic material created especially for manufacturing trailers as an alternative material. The fluted ribs of Piedmont's specialty vehicle headliner, which is made of PolyCor® HL, supports all surfaces, making it stronger than corrugated fiberboard, lighter than wood, and more cost-effective than solid PVC sheets. It also has the advantages of being washable and chemical-resistant.


Toy hauler manufacturers found many benefits in using plastics, with ceiling design being one of those. Hauler and trailer ceilings have often been made of fiber-based materials, but water exposure can degrade these materials over time. As mentioned before, Piedmont Plastics stocks PolyCor HL headliner material, a transportation-grade plastic that takes the place of fiber materials. This is the first commercially available alternative for a water-resistant trailer or toy hauler ceiling.


For years, wood floors were the preferred choice for trailers and toy haulers. But despite its strength, even treated wood will deteriorate over time.

Plastics produce a tough, long-lasting surface that won't rot, rust, or corrode when used as a trailer floor. As a result, trailer manufacturers can extend the length of their product warranties and attract more customers. That is why we introduced PolyCor® P, an all-purpose plastic material that can be used for flooring.

For those that still prefer the wood look, we also offer AquaPlas® SG, which is an industry-leading wood alternative made from upcycled natural organic fibers. It is resistant to water, pests, and rot, yet still easy to process using traditional woodworking tools and machinery.

Lightweight and Fuel-Efficient

Any vehicle's fuel economy suffers while it is towing a trailer. The heavier the haul, the more fuel required. Plastic weighs considerably less than metal, which enables designers to create trailers and haulers with a much lower overall weight. As a result, they produce a lighter, more fuel-efficient, and better-looking final product for their customers.

What Are the Different Types of Toy Haulers?

Toy haulers are, in a sense, miniature RVs or "garages" that follow larger RVs. While they're great for allowing you to carry more on the road, they also allow RV owners to free up space in their main unit by placing non-essentials in the toy hauler.

Typically, there are two types of toy haulers—Class A and Class C. Class A is around 10 feet long, while Class C is eight feet. Each tends to pair up with their relative RV. Larger RVs get the Class A. Slightly smaller ones haul the Class C. In both cases, you get additional space relative to your living-quarters RV.

Trailer Panels and Materials At Piedmont Plastics

Our aim at Piedmont Plastics is to assist our customers in building a better hauler. We provide the products necessary for you to guarantee your floors, walls, and ceilings. Plastics have clear advantages in toy hauler design and have the potential to improve the industry. Contact your Piedmont Plastics sales representative today to learn more about using plastics in trailer and hauler design.

Piedmont Plastics carries a wide range of products, including PolyCor AP that can be applied to various other trailer aspects of modern trailer production. Call to see how we can provide you with the high-quality, dependable products that Piedmont Plastics' clients have come to rely upon for decades.