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

Modular decks for RoRo vessels (non-metallic)

© Uljanik

State of the Art

Steel and partly aluminium are the dominating solutions for RoRo decks. Innovative lightweight steel and steel-plywood decks are occasionally applied at small scale, primarily for liftable (intermediate) decks which do not contribute to global strength. Non-metallic composite sandwich deck panels in a steel frame structure, and few prototype applications at small scale and only one at a large scale (M/V Siem Cicero) exist. Assembly and outfitting processes are largely manual and not adapted to larger economy of scale.


Reduction of the weight of the strength decks with increased flexibility in the ship design due to modular system. Optimising the deck structure design using innovative materials and geometry results in more efficient production as well (shorter lead times, improved reliability, and quality).


The solution is a system for cargo decks based on standard lightweight panels and metallic or pultruded (composite) beams – including corresponding joints and outfitting elements (lashing devices, lifting elements etc.). Within the project, a FRP (fibre-reinforced polymer) pultrusion profile was installed in the top three decks of a car carrier which cover 12600 m² area. The deck arrangement consists of the composite module supported by a steel grillage system. The FRP pultruded profile production preparation activities were performed including the definition and production of the forming dye, preparation of the production facilities, and the FRP pultruded profile production. Several test arrangements are performed to qualify the pultrusion profiles as deck structure, including bonding test, small scale fire test, full scale fire test and mechanical tests. Further, demonstrator tests are planned. The target is to achieve an optimum between weight and payload, and production cost at reduced production lead time and reduced maintenance (corrosion).


There are several thousand m² of cargo decks in typical RoRo ships, the mass of which can be further reduced. The solution can be applied in other shipyards as well as in deck plating for offshore or civil (land based) applications, e.g. bridges. Using synergies and standardisation potential together with RAMSSES component demo cases, the application potential can be further increased.