Shown below is the XPS Core structural foam used throughout the walls, roof, and floor of Torus RV caravans. This closed-cell composite forms the backbone of our timber-free shell, delivering excellent strength, thermal insulation, and moisture resistance.
To maximise these benefits, the walls, floor, and roof are built as a one-piece panel system. This creates a stronger overall structure and reduces the number of joins, which means fewer potential entry points for water ingress.
Each panel is manufactured using a vacuum-bonding process that compresses every layer together and permanently bonds them using two-part SikaForce polyurethane adhesive. That full-surface bond is the key, it’s not just “held together”, it becomes one solid structure.
Because of the way they’re built, these panels can span confidently while still handling the natural movement that comes with off-road travel. You can even stand in the middle of a panel and it will flex under load, then return to its original shape once the weight is removed. With a traditional timber-framed wall, it can flex and spring back but often won’t return perfectly true. With alloy-framed walls, it’s more likely to stay bent once it’s been stressed.
The end result is a caravan shell that naturally wants to hold its shape over time, staying straighter, tighter, and more reliable long-term. That means better durability, less risk of structural fatigue, and more confidence your van is built to go the distance.
