Aluminum has a smaller density than other material, with a lightweight, thus it is a ideal choice for caravan. Mingtai aluminum sheet can be processed to reach a necessary strength for caravan. Features and Applications of Aluminium Sheet for Caravan
What you have in mind to do has been done in the days of vintage caravans, back in 1955 there was a product called "Alply" that was used on gypsy caravans as far as we know it didn't last beyond 1959, so maybe the problems you mentioned were too hard to overcome .....the aluminum was apparently "hot bonded" to the ply.
While it would have saved some money up front, it would have been a much larger maintenance commitment long-term, because wood needs way more love and upkeep than metal. (Duh.) One of the first things was logistical; how to get the sheets of aluminum home so we could put it on the trailer.
The aluminium sheeting for caravans 5000 series and 6000 series aluminum alloy can make the caravans has a weight loss of about 40% than that of traditional steel plate. The aluminum alloy greatly reduces the caravan’s own weight, reduces the fuel consumption, and saves the operating cost.
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Alibaba.com offers 850 caravan aluminium sheet products. About 6% of these are travel trailer, 4% are aluminum composite panels, and 2% are aluminum sheets. A wide variety of caravan aluminium sheet options are available to you, such as coated, anodized, and embossed.
Alibaba.com offers 363 aluminium caravan cladding products. About 28% of these are aluminum composite panels. A wide variety of aluminium caravan cladding options are available to you, such as anodized, brushed, and pvdf coated.
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The question of whether your caravan should be made from aluminium or fibreglass dates back to the 1960s when fibreglass was first put to serious use by manufacturers such as Roadmaster and Spacemaster.
i used to work opposite these guys, as the old company i used to work for anodised their sheets for them. Great products, and good quality. Even though i am still in the aluminium game, the company i work for now doesnt sell sheeting, but still have the contacts to if i need it.