Weight does matter when choosing a flatbed, but it’s not the only thing that should drive your material decision. “Yes, aluminum is lighter. That’s usually where the conversation starts,” said Brad Windy, Director of Freedom Product Engineering at Great Dane. “But in our experience, it’s rarely where it ends.”
Great Dane offers its Freedom line of open-deck trailers in steel, aluminum, and combo configurations for a reason: Every operation has its own priorities. And Windy said there are real-world trade-offs fleets face when they choose between steel, aluminum, or a hybrid construction.
Matching the Material to the Mission
ROI is a big decision when choosing a flatbed material. Each construction has a profile:
- Aluminum: Lower weight, higher corrosion resistance, premium look. Ideal for long-haul freight, northern climates, and image-conscious fleets.
- Steel: Rugged, easier to repair, cost-effective up front. Best for heavy-duty jobs like work on construction sites and uneven surfaces, like gravel roads or dirt.
- Combo: Versatile middle ground. Balances long-term ROI with practical weight and serviceability considerations.
Windy’s advice? “Think about where the trailer’s going to run, what it’s going to haul, and who’s going to maintain it. That’ll usually point you in the right direction.”
And don’t overlook downtime. “If your trailer spends two extra days in a shop because a local outfit can’t weld aluminum, that’s real money lost. Your material choice has to account for that.”
The Material Tradeoffs That Matter
The lighter weight of aluminum can support higher payloads and provide better fuel efficiency. But some customers go with aluminum for more specific reasons, like increased corrosion resistance or reduced maintenance. Others choose it for aesthetic reasons.
“Some fleets tell us that aluminum trailers help attract drivers. They look cleaner and more modern. There’s a recruiting benefit there,” Windy explained.
For operations running in northern states or carrying corrosive cargo, aluminum’s natural resistance to rust becomes a serious advantage. Road salt, fertilizers, or liquid chemicals can eat through steel over time, especially if maintenance lapses. A clean, non-corroded appearance also holds value in resale markets. Then, there’s the payload angle.
“The weight savings from aluminum can give fleets more flexibility,” Windy noted. “If you’re close to maxing out your load with a steel trailer, that extra 2,000 to 2,500 pounds can be the difference between two trips or one.”
Don’t Count Steel Out
Steel still has a strong case, especially for fleets that prioritize durability and repairability.
“Steel is easier to weld in the field without compromising the material’s temper,” Windy explained. “It also shows better fatigue performance under certain conditions. When it cracks, you can sometimes see it coming. With aluminum, cracking can be less obvious until it’s a real issue.”
Field repairability becomes important for operations in remote areas, or fleets that perform their own maintenance and don’t want to chase specialty welding skills. And in certain extreme-duty applications—construction, scrap hauling, or repeated forklift loading—steel can offer more peace of mind.
“A fleet running in rural areas without easy access to a repair shop might be better off with steel,” Windy added. “You’re not going to have an aluminum welder at every repair shop.”
Also, steel trailers can be spec’d for more demanding applications at a lower upfront cost. For heavy-haul or concentrated loads, the upfront savings and ruggedness of steel still appeal to many construction and industrial fleets.
Why Combos Often Hit the Sweet Spot
“The reality is that many customers want the best of both worlds,” Windy said. That’s where combo trailers come in.
Great Dane’s combo flatbeds combine steel and aluminum components to balance weight savings, cost, and durability. Aluminum floors, crossmembers, and side rails cut pounds, while steel mainbeams provide reliable strength in a cost-effective package.
“We see a lot of fleets spec combo trailers to get the corrosion resistance of aluminum where they need it,” he added. “The steel components in a combo trailer are used in areas where we can take advantage of the durability and strength.”
This hybrid approach is especially useful for fleets with diverse routes and cargo. A combo spec may not be the lightest or cheapest in any one category, but it offers a solid balance of features that perform well across multiple operating conditions.
“It gives fleets more flexibility to run different types of freight without feeling like they’re over- or under-built for the job,” Windy said. “And for those watching total cost of ownership, combo specs often pencil out really well over the life of the trailer.”
Real-World Examples and ROI Drivers
Let’s say you’re hauling pipe through the Midwest in winter. The roads are wet, the salt is heavy, and your stops are few and far between. An aluminum trailer might be worth it just to reduce corrosion claims and cleanup time.
On the other hand, a regional construction hauler running in the Southeast might see better ROI from steel. If the trailer’s going to see daily loading from forklifts or grapple arms, the extra toughness and lower repair costs matter more than the weight savings.
For fleets with centralized maintenance and longer trade cycles, aluminum’s longevity may justify the initial cost. For short-cycle fleets or those that rotate trailers more frequently, combo or steel might offer better total value.
More Than a Spec Sheet
For the team at Great Dane, helping fleets spec the right material isn’t about upselling one option over another. It’s about understanding the full picture. The trailer’s job, the environment, the maintenance reality, and the long-term goals.
“We’re not building for a brochure,” Windy said. “We’re building for the road.”
Whether you’re leaning toward aluminum for its light weight or sticking with steel for its ruggedness, the key is clarity on what your trailer needs to do, and how long you need it to last. When it comes to material choices, smarter specs lead to longer service life, more uptime, fewer surprises, and a better bottom line. And that’s what every fleet manager wants.
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