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 research and development 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.
Objective
Introduction of fibre reinforced polymers (FRP) into the yard production process for usage in cruise ships, passenger ferries and gas carriers with the aim to reduce weight (up to 30%).
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 design of the composite wall panels according all technical and process requirements was completed. The evaluation included 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.
An on-board demonstrator was installed on a cruise ship within the RAMSSES time frame. A risk assessment of the application case was initiated with the scope to assess and evaluate if the intended design meets the requirements of SOLAS II-2 and the identification of critical aspects, that have to be investigated within the approval process.
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.