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

Multi material lightweight cabin for passenger ships

© STX France / Bernard Biger

State of the Art

Prefabricated modular cabins have largely replaced the ‘in-situ’ made cabins in cruise ships and ferries. Cabins are usually built without floor (which is still part of the steel structure) – making transport and installation difficult and restrict pre-outfitting. Distribution infrastructure (cables, pipes, ventilation) is usually integrated in the steel structure, but not in the cabins. Windows and other sensitive elements can only be installed at a late stage, when the cabin is fully connected and integrated. Hence, the lightweight and pre-outfitting (lead-time and cost reduction) potential of fully integrated pre-outfitted cabins is currently not fully exploited.

Within the RAMSSES project this demo case aims to design an innovative cabin and its interface to ship structure to generate a novel ship architecture, reducing weight, size, costs, production times, maintenance and refurbishment effort. As for the weight, we estimate a reduction of about 25% per cabin. One ton of weight saving per cabin seems realistic.

Solution

Currently, we concentrate on the replacement of a steel deck by a composite structural deck including some major functions of the floor of the bathroom and the configuration of pipes and ducts. To the best of our knowledge, there is no composite material available “from the shelf” which fulfils current SOLAS regulation. In that context, we decided to work with innovative materials which are still under an acceptable development maturity level. According to the good preliminary results obtained by the RAMSSES partners PodComp, NetComposites and BALance working on bio-based composite as well as from HUTCHINSON () with ZALTEX material) and regarding fire tests compliancy, we assume that within the time frame of RAMSSES project the composite products might be fully or partially qualified second SOLAS and IMO requirements. Therefore, to ensure a good understanding and comparison, we decided to study two options for the structural deck, one using ZALTEX from HUTCHINSON and another one using a composite that applies PFA resin. These two options will be properly tested for fire regulations and for mechanical behaviour, the latter with JULES VERNE institute, to ensure a proper evolution and potential application of composite deck to the future cabin.

Potential

Fostering the modular approach, which allows combining standard elements to customer specific solutions. Prefabricated, self-sustainable cabins can be used for a variety of PAX ships, offshore accommodation, but also land-based buildings and ad-hoc (emergency) accommodation.