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

Lightweight aluminium and composite walls for work boats

State of the Art

In small to medium size workboats single skin extruded aluminium panel are used for the superstructure and the deck houses. The single skin panels are either welded on top of the web frames or are running through the cut-outs in the web frames. When welded on top of the web frames relatively short weld lengths are achieved that might arise strength and fatigue issues if large shear forces are transmitted through the frames. Welding of the single skin panels to form an assembly introduces weld distortions. In addition to visual appearance, the weld distortions can deform the deckhouses of a relatively low stiffness. Thermal and fire insulation of the structures is time consuming as the panels are first insulated in between the stiffeners and secondly on top of the stiffeners.

Solution

In order to reduce the production lead time, reduce the weight and weld distortions, a new solution based on aluminium and composite sandwich panels is proposed. The focus is on the superstructure and on the deckhouse. In a first solution, double skin extruded aluminium panels are proposed that would allow more time efficient fire and thermal insulation of the deckhouses as the tedious insulation between the stiffeners is not necessary. Means to achieve different fire classes will be studied. However, the main drawback of the aluminium sandwich panels is minimal to no weight saving as double skin panels cannot compete with already relatively thin single skin panels. Second option is based composite panels, that would allow significant weight saving compared to conventional solution.

A joining solution for the panels will be studied. For aluminium panels a “clip” joint based option is proposed, where only the inner skin of the panels is to be welded and the outer skin is joined by clip-joint. This would allow to reduce weld distortions and improves the visual appearance of the of exterior of the final assembly. For composite panels, more conventional solutions are to be finalized. With sandwich panels the interior surface finish can be achieved more efficiently as the double skin panels result in flush surface. The panels allow achieving higher bending stiffness with the same mass and allowing continuous welding between the stiffeners and the web frames and thus, assuring better transmission of the forces between the stiffeners and the web frames. The innovative design will be evaluated with respect to the conventional design based on single skin panels.

Potential

Wide application potential especially for numerous small shipyards in Europe which produce a huge number of small vessels, often for local markets.