We at Urban Caravans set out to build the most perfect semi off-road and off-road caravans. With this goal in mind we started off with an Aluminium - Tig Welded frame and built all other elements to the highest spec possible. We continue to innovate and introduce new construction methods to ensure we future-proof our caravans.

Steve - Founder of Urban Caravans

Our Construction

All caravans built by Urban Caravans have a specially and uniquely developed Aluminium – Rot Free Frame that uses Tig Welds for durability and rigidity and Lock Bolting for off-road flexibility and stress absorption. The frames are then attached to the chassis using Z Channel grooves, that ensure the longevity and off-road prowess of all caravans built by Urban Caravans. Our interiors are also up to the task using our specially developed ‘Glue It, Screw It, Seal It’ manufacturing process.

Rot Free

Having an Aluminium frame means that our caravans are built for longevity, endurance and off-road ability. One of the biggest issues facing traditionally built wooden frame caravans is damage caused by water ingress. This rots the frame and renders the caravan useless. FIND OUT MORE.


A Tig Weld avoids the use of rivets when constructing the Aluminium Frame. By Tig Welding the entire aluminium frame, there is no need for any rivets or staples and the wear and tear (such as stress cracking to the surrounding Aluminium) is avoided. FIND OUT MORE.

Z Channel

By using a Z Channel when joining the chassis with the frame, the frame bolts onto the chassis using the overhangs. This is a more secure way to merge the frame and chassis and ensure durability and flexibility at the same time. FIND OUT MORE.

Glue It, Screw It,
Seal It.

All furniture is cut by CNC, we use a basic tongue and groove technique in all joins. This is then followed by our proprietary modified 3-part process of ‘ Glue It, Screw It, Seal It.’ The interiors of our caravans must be made to a level that withstands semi off-road and off-road conditions. FIND OUT MORE.

Our experienced TIG Welder welding the frame of our Tungsten X-Treme caravan.
Rot Free Frame. Built from aluminium, our caravans are not susceptible to rot caused by water intrusion.
Glue It, Screw It, Seal It. Your interior needs to match the tuff exterior.

How We Build Our Caravans

To find out more, simply click on the links below.


Find out about our Tig Weld process for joining Aluminium and how, in combination with Lock Bolting, you get the perfect offroad caravan.

Rot Free

Want to know why Aluminium Frames are the right way forward? How about starting with their longevity and the fact that they are rot free.

Z Channel

If you want to go off-road then you will need the marriage between the chassis and the frame to utilise the right type of joins.

Glue It, Screw It, Seal It.

How do you ensure that the whole caravan is durable, not only the TIG welded aluminium frame? By using our tried and tested method of course.


Unlike other manufacturers, Urban Caravans incorporate insulation in as much of the chassis as possible for increased comfort levels.

Dust Suppression

Our optional dust supression system provides you with peace of mind and a cleaner interior when traversing the dusty Australian outback.

Our Industry Partners & Links


Frequently Asked Question

Aluminium Frame caravans are longer lasting, are not susceptible to rot and better suited for semi off-road and off-road caravaning. 

Tig Weld is the way to go when it comes to joining aluminium frames. The legacy manufacturing process of using rivets leaves the frame susceptible to stress fractures to the aluminium around the rivet.

Using Z Channels, the frame is connected to the chassis via more touch points, unlike the old practice of bolting the frame onto the chassis just by laying it on top. 

Yes. Caravans built by Urban Caravans come with a warranty. For more information please visit our warranty page or speak to your preferred dealer.

Urban Caravans are Australian Made and Australian Owned. The main production facility is located in Melbourne.

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