Hiper Conference 17-19/10/2016 Cortona, Italy

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1 Composites Future Materials for High Performance Boats Hiper Conference 17-19/10/2016 Cortona, Italy Credit: Ozata Shipyard Julien Sellier Managing Director STRUCTeam Ltd Copyright STRUCTeam Ltd Slide: 1

2 S T R U C Te a m ( S T L ) Composites Solutions Provider We help our clients make better decisions, reduce costs, improve efficiency, select and develop appropriate technologies for their composite business. Credit: Tri-Marine Credit: Atlantic Eagle Shipbuilding Independent Composite Consultancy 150+ Projects Completed since 2010 across market sectors We enable composite applications! Copyright STRUCTeam Ltd Slide: 2

3 I n t ro d u c t i o n Objectives: 1) Brief Intro on Composites 2) Opportunities for Composites in Marine Sector 3) Method to Assess Opportunities Copyright STRUCTeam Ltd Slide: 3

4 C o m p o s i t e s Materials B787 Process Design Is It Really Easy to Adopt? Copyright STRUCTeam Ltd Slide: 4

5 T h e E n g i n e e r s M a t e r i a l Pa l e tte Fibres Resins Cores Manufacturing Process Adhesives What Materials Shall I Use? Copyright STRUCTeam Ltd Slide: 5

6 M a n u fa c t u r i n g Te c h n o l o g i e s Wet lamination Press Infusion Pultrusion Prepreg Automation What Process Shall I Use? Copyright STRUCTeam Ltd Slide: 6

7 N e e d fo r D e d i c a t e d E x p e r t i s e a n d S o f t w a re S o l u t i o n s Which Combination of Materials & Processing should I choose? Copyright STRUCTeam Ltd Slide: 7

8 S O L A S Re g u l a t i o n s Ship structures must be constructed with steel or other equivalent material Equivalent material = non-combustible material However it is possible to go through case-by-case certifications with certification bodies as DNV GL, Lloyd s Register, Bureau Veritas Copyright STRUCTeam Ltd Slide: 8

9 N e e d fo r D e d i c a t e d E x p e r t i s e a n d S o f t w a re S o l u t i o n s Large number of materials to choose from Lots of Possibilities for Resin, Fibres, Core Lots of Manufacturing Processes Possible Certification Can Be Difficult Not Easy & Can be Expensive Need of Dedicated Expertise Different From Other Isotropic Material Need for Dedicated Software Solutions Copyright STRUCTeam Ltd Slide: 9

10 C o m p o s i t e M a t e r i a l Pe r fo r m a n c e Specific strength (kpa.m^3/kg) CFRP GFRP Steel Aluminium Specific stiffness (MPa.m^3/kg) CFRP GFRP Steel Aluminium Fire retardancy Traditional Metals and Composites Comparison CFRP GFRP Steel Aluminium Specific strength Specific stiffness Indicative Material Cost ( /kg) CFRP GFRP Steel Aluminium Corrosion resistance Fatigue resistance Cost Specific Fatigue Strength at 10^7 cycles (kpa.m^3/kg) CFRP GFRP Steel Aluminium Copyright STRUCTeam Ltd Slide: 10

11 Performance C o m p o s i t e s O p p o r t u n i t i e s Optimised Products Special Requirements Low Regulated, High Strength & Stiffness Driven. Production Products Geometry, Cost and Weight Driven Regulated Products Weight Driven Price Copyright STRUCTeam Ltd Slide: 11

Performance C o m p o s i t e s O p p o r t u n i t i e s Olympic

Racers Ferries Performance & High Quality Cruisers Special

Geometry, Cost Sailing, and Weight Cruiser RIB s Power Driven

12 Performance C o m p o s i t e s O p p o r t u n i t i e s Olympic Classes Surfing Cat Hobby Competition Optimised Products Power Racers Ferries Performance & High Quality Cruisers Special Requirements Ocean Racer Not Regulated, AC Yachts High Strength Mega & Stiffness Sailing Driven. Yachts Military Small Production Products Cabin Boats Outboard Geometry, Cost Sailing, and Weight Cruiser RIB s Power Driven Shipping And Components Work Boats Regulated Products Weight Driven Mega Power Yacht Price Copyright STRUCTeam Ltd Slide: 12

13 M a r i n e S e c t o r Leisure Market % Market size 7 billion Commercial Market % Market size 29 billion Regional Share Source: RINA Source: UCINA Copyright STRUCTeam Ltd Slide: 13

weight saving compared to steel Reduced need for maintenance Perceived Entry Barriers Heavily

14 Re g u l a t e d P ro d u c t s E xa m p l e : H i g h S p e e d Fe r r i e s Benefits of Composites Trade off between equipment and performance Increased Fuel Efficiency Up to 50% weight saving compared to steel Reduced need for maintenance Perceived Entry Barriers Heavily Regulated Market Composites are expensive Multihulls HSC Electric Ships Copyright STRUCTeam Ltd Slide: 14

S p e c i a l Re q u i re m e n t s E xa m p l e : Military Ve s s e l s Performance

from specific regulations High Shock Resistance Increased Speed from Reduced Weight

Will the staff be trained in composite? Is the experience there?

15 S p e c i a l Re q u i re m e n t s E xa m p l e : Military Ve s s e l s Performance Stiffness (Weapons) Ballistics Protection Low Radar and Magnetic Signature Opportunity from specific regulations High Shock Resistance Increased Speed from Reduced Weight Perceived Entry Barriers Repairability, Maintenance and new Is it really new? Will the staff be trained in composite? Is the experience there? HSC Military Vessels Ultra-efficient ships Patrol Boats Intelligent + connected ships Copyright STRUCTeam Ltd Slide: 15

16 H e av i l y Re g u l a t e d Ve s s e l s E xa m p l e : C o m m e rc i a l S h i p p i n g Perceived Entry Barriers for composites How do I cope with regulations? How do I maintain/repair vessels? What about the current fleet? Copyright STRUCTeam Ltd Slide: 16

. Increased Payload OR Increased Fuel Efficiency Increased Stability from lower COG Reduced Maintenance Example:

17 H e av i l y Re g u l a t e d Ve s s e l s E xa m p l e : C o m m e rc i a l S h i p p i n g Lightweight Superstructures, Radar Masts, Rudders, Cargo Hatches Etc.. Increased Payload OR Increased Fuel Efficiency Increased Stability from lower COG Reduced Maintenance Example: Composite Cargo Hatches Easier crane handling and lighter motors No corrosion means better seal performance - reducing risk of cargo damage Shipping Copyright STRUCTeam Ltd Slide: 17

18 A s s e s s i n g O p p o r t u n i t i e s Business Case: Patrol Boat 60 feet 40 knots Credit: ARES Shipyard Inc. Material and Process Matrix (Reference Material : Aluminium) Reinforcement material Glass Carbon Process Core material Infusion Prepreg PET G/INF/PET C/INF/PET C/PP/PET PVC-Balsa G/INF/ PVC-B N/A N/A PVC G/INF/PVC C/INF/PVC C/PP/PVC Copyright STRUCTeam Ltd Slide: 18

19 A s s e s s i n g O p p o r t u n i t i e s Business Case: Patrol Boat Weight vs material cost Copyright STRUCTeam Ltd Slide: 19

20 A s s e s s i n g O p p o r t u n i t i e s Business Case: Patrol Boat Return on investment 30-year budget for 50% utilization Copyright STRUCTeam Ltd Slide: 20

C o n c l u s i o n Opportunities Cost-effective on a Medium-term basis -

maintenance Large freedom from variables Decrease total weight Shortage in

crafts Challenges Requires a well structured process for decision and design

21 C o n c l u s i o n Opportunities Cost-effective on a Medium-term basis - Increase in fuel efficiency - Increase in payload - Increase in stability Low maintenance Large freedom from variables Decrease total weight Shortage in traditional materials (Aluminium, Wood, Steel) Useful for niche markets/special crafts Challenges Requires a well structured process for decision and design SOLAS Regulations on main components Initial Cost of Materials Copyright STRUCTeam Ltd Slide: 21

22 A ny Q u e stions? Julien Sellier julien.sellier@structeam-ltd.com STRUCTeam Ltd Copyright STRUCTeam Ltd Slide: 22

DEVELOPMENTS IN FIRE PROTECTION OF FRP COMPOSITE VESSELS

DEVELOPMENTS IN FIRE PROTECTION OF FRP COMPOSITE VESSELS Paper presented at the RINA Conference Innovation in High Speed Marine Vessels, Freemantle, Australia, 28-29 th January 2009. SUMMARY One of the