What are the benefits and downsides to aluminum construction vs wood construction in a travel trailer?

You really have to look at more than just alum vs. wood as I would say aluminum is superior to wood in almost all instances. However, when you say stick and tin vs. aluminum and fiberglass it is a different animal. Aluminum and fiberglass imho is much nicer looking, and is usually lighter and easier to maintain. The aluminum also will not rot like wood can. The problem with fiberglass is delamination. The cost of wall repairs with a fiberglass trailer are insane $4k-$10k in some instances. Where taking off the tin sheeting seems fairly easy and much cheaper.

WorkmenshipSome of the best trailers made are wood framed, as are some of the worst.Aluminum is easier to control the quality, so many have switched

I've been told fiberglass trailers are "generally" aluminum frame and aluminum sided trailers are "generally" wood frame. Probably not true in 100% of the cases but generally true. I've owned both types and prefer the fiberglass sided trailer.

This from NUWA; Why doesn't NuWa use an all aluminum structure like popular Indiana manufacturers? NuWa made the decision to begin the use of aluminum structure based on marketing and the fact that many people were concluding that an "aluminum caged" product was superior in construction technology, weight and strength. Our 40+ years of experience as a leader in 5th wheel design suggests that may be "flawed" information. We have proven that wood construction need be no heavier or less strong than aluminum construction, that is built properly. We now build both materials, and are comfortable doing either, however our opinion is still that wood construction provides a superior product, and today we use both in the construction of our trailers. The strength of the NuWa trailer is actually created by the superior and light weight Blue Dow foam lamination concept.NuWa uses an aluminum substructure in the sidewalls and ends of the coach only. No aluminum in the floors or attics, where metal promotes conduction of cold and moisture resulting in condensation. 90% of the walls are Blue Dow Structural Foam, rather than wood or aluminum. This creates a superior insulation and the only product with a guaranteed sidewall R Factor. (Water absorption in standard white foam reduces R Factor over time, and the use of Blue Dow Structural Foam eliminates this problem.) NuWa's aluminum substructure sidewall is actually a "hybrid" wall, as we core fill the aluminum with wood in those areas where additional strength is required, because aluminum will not hold a screw. Not so with the lower priced brands. With NuWa's combined use of wood and aluminum substructure, you get a superior product because of NuWa's unique Blue Dow foam vacu-bond process, which makes the sidewalls virtually resistant to water penetration. I've had two wood framed trailers and three wood framed TCs and two aluminum framed trailers. We lived in a foam core aluminum framed unit for one winter. Never again. If I had the money to buy a new unit its going to be a wood framed unit.

Aluminum vs Wood Construction? | Good Sam Community

spoon059
Explorer II
May 16, 2014
I thought about aluminum framing, but then I thought a little harder... The wall studs may not rot if (when) there is a leak, but that water has to go somewhere. Its going to go to the floor and rot. When the floor rots, you have substantial costs to repair.

I had a small leak in my back corner this past winter. I pulled out the tub wall and replaced the rotted 2x2's myself. Glue and wood staples, no welding needed. The 2x2's appear to have absorbed all the water, as the rot was mostly in the upper 2/3's of the wall. With aluminum, that water would have gone all the way to the wood floor and rotted out the floor. It would have taken a long time to figure out the floor was rotted, at which time it would have been a HUGE undertaking to rip up the bathtub, sink, wall, flooring to expose the damage.

Until the frame and structure is built from materials that are 100% impervious to water, you will have to contend with damage from leaks. My personal experience is that wood is easier and cheaper for a DIY guy to fix himself.
camperpaul
Explorer
May 16, 2014
With either one the studs and rafters conduct heat.

Because aluminum is a better conductor, the RV will be colder in winter and warmer in summer than it would be if the framing were made of wood.
garyhaupt
Explorer
May 16, 2014
If one were to do a search of repairs posted to the Forum, one would find a large-ish number of front cap repairs..and recounts of the cost and or work involved, in removing and replacing the wood. With aluminum..you pull out and replace the wet insulation. Now..I am not an RV repair person, but I have paid for that..and replacing insulation is buckets cheaper than replacing the wood framing. And it's not the wood...it's the $100.00+ an hour labour rate.

Of course, no matter which material, one still has to locate and stop the water ingress.

Gary Haupt

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