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


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 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 not fully exploited.


Design innovative cabins and ship structure interfaces to generate a novel ship structure architecture, reducing weight, size, costs, production times, maintenance, and refurbishment effort. This includes the design of a six-side cabin module for full functional modularity, the use of innovative hybrid or composite lightweight components and modified network integration into the cabin modules.


The outfitting sequence is modified in order to install cabins that are as far as possible finished and ready for final inspection by the customers without needing any work inside. The floor and the bay window are added to the existing prefabricated cabin. Two solutions were evaluated for floor material: Ecopreg and Zaltex. Both materials have been assessed through the mechanical test and analytic calculations and proofed a weight reduction of the overall cabin structure. Ecopreg is showing the best potential and further work is needed to ensure fire capabilities.


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.