Van Assembly Technology At ICU, we specialize in the design and production of high-performance mobile units—ambulances, mobile laboratories, command and control vehicles, mobile clinics, and special-purpose shelters. At the heart of this capability lies our advanced van assembly technology.
Every ICU vehicle is not just a means of transport—it’s a mission-critical platform designed for reliability, safety, and seamless functionality. Our assembly process combines modular design, industrial-grade materials, and craftsmanship backed by precision engineering, ensuring each unit meets the rigorous demands of our clients in defense, healthcare, energy, and humanitarian sectors.
From Chassis to Completion – ICU’s Full-Cycle Van Assembly Technology Process
We start with certified chassis platforms from trusted global brands (e.g. Mercedes-Benz, MAN, Toyota, Ford, IVECO), and transform them into specialized vehicles by integrating:
- Custom-built body structures
- Insulated sandwich panels
- Technical furnishings and operator workstations
- HVAC and power systems
- Medical, laboratory, or communication equipment
Every stage is handled in-house at our production facility, ensuring tight quality control, rapid execution, and customization flexibility.
1. Chassis Preparation and Base Frame Installation
The assembly process begins with structural evaluation and chassis adaptation. For vans or box-body trucks, ICU installs a reinforced subframe, securely mounted to the chassis with vibration dampers and protective corrosion coatings.
Key steps include:
- Alignment check and leveling
- Welded or bolted subframe installation
- Mounting brackets for auxiliary systems (tanks, batteries, equipment trays)
2. Sandwich Panel Body Construction
The main body of our mobile units is constructed from ICU’s own sandwich panels, produced in-house using:
- PUR/PIR insulation cores for thermal control
- Powder-coated steel or fiberglass skin layers
- Tongue-and-groove joint systems for airtight sealing
The body is assembled with:
- Reinforced corner profiles
- High-grade sealants and fasteners
- Integrated cable ducts and service hatches
Result: a durable, weather-resistant, and hygienic mobile environment, compliant with EN 1789, ISO 9001, and other sector-specific standards.
3. Floor, Wall & Ceiling Finishing
Inside the van, ICU builds a fully sealed interior space using:
- Waterproof, anti-slip flooring with chemical resistance
- Fire-retardant wall panels with antibacterial surfaces (for medical units)
- Drop ceilings with integrated LED lighting and cable runs
Interior layouts are custom-designed using CAD software, allowing us to:
- Maximize operator space
- Ensure equipment accessibility
- Facilitate cleaning and maintenance
4. Equipment Installation and Integration
Depending on the vehicle’s purpose, ICU integrates various specialized systems during assembly:
● Medical Vehicles:
- Oxygen systems with pressure regulators and wall ports
- Patient stretchers and seating with crash-tested mounts
- Defibrillators, suction units, ECG monitors
- UV sterilization and wash stations
● Mobile Labs:
- Fume hoods and HEPA filters
- Benchtop analyzers and workstations
- Chemical storage with ventilation
- Shock-absorbing equipment racks
● Command Units:
- Communication racks and control panels
- Pneumatic masts and antenna systems
- Redundant power and data cabling
- Smart climate management systems
All equipment is installed in accordance with manufacturer specs and international safety standards, ensuring both functionality and user safety.
5. Electrical and Power Systems
Each ICU vehicle is equipped with a multi-source power system, which may include:
- External 230V/400V power inlets
- Onboard diesel generator (soundproofed)
- Deep-cycle battery packs
- Inverter-charger systems (DC/AC)
We implement:
- Dedicated power distribution units (PDUs)
- Surge protection
- Backup UPS units for critical loads
- Color-coded and labeled wiring
The electrical installation is tested with digital multimeters, insulation testers, and load simulators before vehicle delivery.
6. HVAC and Climate Control
Proper environmental control is essential, especially for medical and analytical applications. ICU installs:
- Split-type or rooftop air conditioners
- Diesel heaters or heat pumps
- Air filtration and overpressure systems
- Climate monitoring sensors
These systems are tailored to operate between -30°C and +50°C, making the vans suitable for use in all climate zones.
7. Final Inspection and Quality Control
Before delivery, every ICU vehicle undergoes a comprehensive inspection protocol:
- Structural integrity verification
- Electrical continuity and grounding test
- HVAC and plumbing function tests
- Equipment calibration and user simulation
- Visual and functional walkthrough
A quality control checklist, serial number traceability, and certificate of conformity are issued with every unit.
Modularity and Fast Maintenance
ICU assembles its vans using a modular approach, which allows:
- Quick reconfiguration for different missions
- Fast replacement of damaged components
- Simplified upgrades over the product lifecycle
This is especially valuable for fleet operators, military clients, and humanitarian agencies working in dynamic field conditions.
Safety Comes Standard
All ICU vehicles are built with safety-first principles, including:
- Anti-slip entrance steps and grab handles
- Emergency exits and warning signage
- Fire extinguishers and smoke detectors
- Crash-rated seat bases and cabinet locks
- Sealed compartments for hazardous goods
Additionally, all installations comply with electrical safety standards (IEC/EN) and EMC guidelines, minimizing interference and failure risks.
Global Deployment and Support
ICU van assemblies are exported worldwide and adapted for:
- Right- or left-hand drive
- European, Gulf, or African climate zones
- Local voltage/frequency standards
- Special military, medical, or customs regulations
We provide documentation in multiple languages, remote support, and after-sales training upon request.
Conclusion: ICU Van Assembly Technology – Engineered for Reliability, Built for Purpose
From raw chassis to mission-ready vehicle, ICU’s van assembly process ensures precision, speed, and durability. With a focus on custom solutions and high-quality standards, our vehicles serve with distinction in healthcare, defense, and humanitarian missions around the globe.
Contact ICU today to request technical drawings, a factory visit, or to discuss a custom vehicle configuration tailored to your operations.
