Truck Mattress Foam Custom Mattresses for Sleeper Cabs
Any long-haul truck driver will understand the importance of a high-quality truck mattress. To stay alert on the road, it is especially important that lorry drivers get good quality sleep and rest.
If you are looking to replace your current foam truck cab mattress or need a new one custom-made, we can help. We supply mattress foam on a one-off basis or for full fleets. For the best night’s rest during those long-haul journeys, choose GB Foam Direct.
- Driver fatigue is a genuine road safety issue: According to RoSPA (with research from the UK’s Department For Transport) around 1,300 injury collisions in Great Britain in 2022 involved fatigue, and research suggests it may be a factor in up to 20% of all road collisions.
- Sleeper cab bed sizes vary a lot, even within one manufacturer’s own range, so a generic “truck mattress” rarely fits properly.
- GB Foam Direct cuts foam to your exact measurements and shape, so the mattress fits your specific cab regardless of make or model.
- We supply single mattresses or full fleet orders, with next-day dispatch on orders placed before 11am, Monday to Thursday.
Why Driver Rest Matters
Fatigue is a real and measurable risk on UK roads. In 2022, an estimated 1,300 injury collisions in Great Britain involved driver fatigue as a contributory factor, and researchers believe the true figure could be higher still, since fatigue is much harder for police to detect or record than alcohol or drugs. Some analysis suggests fatigue may be a contributory factor in up to 20% of all road collisions, and up to a quarter of fatal and serious ones.
Professional drivers are not immune to this. Research cited by RoSPA found that around 40% of sleep-related collisions involve someone driving a commercial vehicle, a disproportionately high share given how few vehicles on the road are HGVs. Long, monotonous motorway driving, night shifts and irregular hours all raise the risk.
Those who drive for extended periods (10 consecutive hours or more) significantly increase their risk of a collision. EU Drivers’ Hours rules require that all drivers get a consecutive 11-hour rest in each 24-hour working period.
During these rest periods, drivers need to actually rest, in a way that is comfortable and genuinely restorative. This protects a driver’s physical health and helps make sure fatigue does not build up over a trip. A properly fitted, supportive mattress is a simple, practical part of that.
Custom Truck Mattress Foam: Any Shape, Any Size
GB Foam Direct offers a bespoke foam cut to size service. This means we can provide the foam you need no matter what size or shape of truck mattress you require. Ordering only takes five simple steps.
Choose your foam shape: a standard rectangle is our sofa cushion foam template, we have a variety of shapes to choose from or a fully custom option if your bunk is an irregular shape.
Enter your measurements: length, width and thickness in mm, cm or inches. For an irregular cab shape, choose the custom shape option and upload a diagram, or post one to us.
Select your foam grade, matched to the firmness and durability you want for daily use on the road.
Choose any add-ons you need for your order.
Place your order. Orders placed before 11am, Monday to Thursday, are shipped for next-day delivery as standard.
How to Measure Your Sleeper Cab
We do not ask for your old mattress to be sent in for reference. For most orders, all we need is your own measurements. A diagram is only required if you are using the custom shape option, and photos are entirely optional if you would like our team to take a look via email before you order.
- Measure the length, width and thickness of the space with the old mattress removed, so you are measuring the bunk itself rather than the old foam as this can become misshapen. If you have an existing cover, this can also be measured.
- If the bunk is a standard rectangle, that is all you need. Enter your measurements against one of our foam shape templates and you are ready to order.
- If the bunk has curved corners that don’t match our shape templates, wheel arches or any other irregular sections, choose our custom shape option instead. This requires a diagram with your measurements marked on it, which you can upload or post to us.
- Double-check your thickness measurement against your cab’s headroom, especially if you are adding a memory foam topper on top of a base layer.
If you are ever unsure about a measurement or a shape, you are welcome to email us photos before placing your order and our team will take a look. Our general guide to measuring foam cushions covers the same measuring principles in more detail.
Truck Mattress Shapes We Can Provide
Because GB Foam Direct cuts foam to size, you can order a truck mattress (also known as a lorry mattress, HGV mattress or sleeper cab mattress) in practically any shape you need. This means you can buy a replacement foam mattress for truck makes including DAF, Iveco, MAN, Mercedes, Renault, Scania and Volvo, among others.
Here are some of the truck models our customers commonly order for:
- DAF XF 105 / 106
- Iveco S-Way
- Iveco Stralis
- MAN TGA / TGX
- Mercedes Benz Atego
- Mercedes Benz Actros MP2 / MP4
- Renault Magnum
- Renault T380 / T440
- Scania R480
- Scania R2010
- Volvo FH 2017
- Volvo FH Globetrotter XL
If your truck is not on this list, that is not a problem. Because every mattress is cut to your own measurements, the make and model does not limit what we can produce.
Choosing the Right Foam Grade
A truck mattress gets slept on every night by a professional driver, so it needs to hold its support for years, not just feel comfortable in the showroom. We generally recommend a firmer, higher-density base layer topped with a softer comfort layer, the same dual-layer approach we recommend for campervan mattresses.
| Layer | Recommended grade | Why |
|---|---|---|
| Base, over 4in thick | GB 33M (Average Medium) | A supportive, durable base for nightly use without feeling too firm. |
| Base, under 4in thick | GB 33H (Average Hard) | Thinner foam needs more density to avoid bottoming out and losing support. |
| Upgrade base | GB 39H (Luxury Firm) | A firmer, longer-lasting option for drivers who want extra support. |
| Comfort topper | GB 55M (Memory Foam) | At least 5cm thick, laminated to the base on request during ordering. |
These are our general recommendations, not a fixed rule. If you are unsure which grade suits your build or sleeping position, our full range is on the upholstery foam sheets page. This will provide further information about the foam types we offer. We also provide a detailed break down of each foam grade and their suitability during the cut to size ordering process. If you’re still unsure, feel free to give our team a call and we will talk it through with you.
Why Sleeper Cab Bed Sizes Vary So Much
Manufacturers rarely publish exact bed dimensions, and the ones you do find online are often inconsistent between sources. What is well documented is how much bed size can change even within a single manufacturer’s own cab range. Volvo’s official cab specification sheets are a useful, verifiable example:
| Cab | Lower bunk (max) | Upper bunk |
|---|---|---|
| Volvo FH Globetrotter XL | 81.5cm wide x 200cm long x 16cm thick | 60cm wide x 190cm long x 10cm thick |
| Volvo FH16 Globetrotter XXL | 106.5cm wide x 213cm long x 16cm thick | 60cm wide x 190cm long x 10cm thick |
That is a 25cm difference in lower bunk width and a 13cm difference in length, on cabs from the same manufacturer and the same FH range. Change manufacturer, model year or trim level and the numbers move again. Rather than guess, or order a “standard” truck mattress that may not fit, provide your own measurements using our foam cut to size service and we’ll cut the foam to match exactly.
Frequently Asked Questions
What size is a sleeper cab mattress?
It depends entirely on the truck. Even within one manufacturer’s range, bed sizes vary considerably. Volvo’s own specification sheets, for example, show a lower bunk of 81.5cm x 200cm in the FH Globetrotter XL cab, rising to 106.5cm x 213cm in the FH16 Globetrotter XXL cab. Because sizes are so inconsistent between makes, models and cab trims, the safest approach is to measure your own bunk rather than rely on a generic size.
Can I get a custom shape, not just a rectangle?
Yes. Alongside standard rectangular foam, we offer a wide range of cut to size templates and a fully custom shape option. For a custom shape, you can upload a template or post us a physical copy, and specify the maximum length, width and thickness you need.
Do you supply truck mattresses for fleets?
Yes. Whether you need a single mattress or foam for a full fleet of HGVs, our sales team can help, and can offer a greater discount on larger fleet orders.
How quickly will my truck mattress be delivered?
Orders placed before 11am, Monday to Thursday, are shipped for next-day delivery as standard.
Why does a comfortable mattress matter for driver fatigue?
Fatigue was a contributory factor in an estimated 1,300 injury collisions in Great Britain in 2022, and research suggests it may play a role in up to 20% of all road collisions. Commercial drivers are disproportionately represented in sleep-related collisions. A supportive, properly fitted mattress will not fix a bad schedule, but it makes the rest you are legally required to take more likely to actually be restful.
Speak to Our Experts
Whether you are an individual driver searching for a high-quality truck mattress, or you manage a fleet of drivers, we can provide the custom-cut foam you need. Call us on 01494 441177 or visit our contact page to get in touch.
Cameron has emerged as a key marketing expert since joining GB Foam Ltd in 2017. A graduate of the University of Winchester, with a professional background in Public Relations; he has combined his content writing and brand awareness expertise with an in-depth knowledge of foam products and foam conversion technology to enhance the company’s marketing strategies and industry presence. Cameron has led numerous marketing campaigns, in both B2B and B2C segments, to further brand recognition and open up new business avenues worldwide.