Modular RoRo deck

Modular decks for RoRo vessels (non-metallic)

Custom-made hull

Custom made hull for offshore vessel

Fully outfitted and modularised cabin

Multi material lightweight cabin for passenger ships

Panel system (bio-based and other)

Lightweight components for high loads and fire class

Composite block on steel deck

Composite superstructure module on steel deck for multi purpose vessels

Versatile walls

Integration of system for internal walls and superstructure
of cruise ships into shipyard processes

Lightweight rudder flap

Lightweight rudder flap

3D-printed propeller blade

Propeller blades by additive manufacturing

Panel system (truss structure)

Modular light system for less critical internal walls and superstructure

Aluminium composite panels

Lightweight aluminium and composite walls for work boats

High tensile steel decks

Lightweight decks using high tensile steel in cruise ships

Design details (high tensile steel)

Highly loaded structural details from high tensile steel
in passenger and research vessels

Patch repair - composite overlays

Composite overlay to repair and improve metallic and
non-metallic structures

RoRo deck

custom-made hull

cabin system

aluminium panels

superstructure

versatile walls

rudder flap

propeller blade

truss structures

bio-based panels

steel decks

steel details

patch repair

Integration of system for internal walls and superstructure of cruise ships into shipyard processes

© Meyer Werft

State of the Art

Vast know-how, comprehensive existing approvals and established processes on steel and aluminium are the reasons why current applications are dominated by those materials. Functional feasibility of non-metallic applications (mostly foam core sandwiches) has been shown in R&D projects and limited industry applications. An industrialised process chain, including inspection and repair, is largely missing. External insulation and extensive approval requirements inhibit a wider application and make it economically unfeasible.

Solution

Using results of the components development in this project, the focus is on evolving highly efficient shipyard processes for adaptation, assembly and outfitting of a modular system, and integrating this into the overall ship design and structures. The latter includes proof of feasibility for less critical mass applications (superstructure and internal walls) considering requirements with respect to strength, fatigue, fire resistance, comfort, optical appearance, ease and cost efficiency of shipyard processes. A concept of work sharing along the supply chain is elaborated with component suppliers. The new solution will provide increased flexibility in design, reduced weight, fuel demand and maintenance cost, allowing pre-outfitting and pre-fabrication of larger blocks.

Potential

Application potential of lightweight modular system in walls and superstructure reaches several thousand m2 in modern cruise ships. The system can be applied in other shipyards and ship types like ferries, yachts and offshore accommodation, as well as in land-based buildings. Highly efficient processes and pre-approval will pave way for the wider application of non-metallic and multi-material structures in other parts of the ship, including critical applications.