engineering, production and life -cycle management for the ... · structural calculation,...

Engineering, production and life-cycle management for

the complete construction of large-length FIBRE-based

SHIPs

D7.2 (WP7): Engineering and production of the demonstrator

Responsible Partner: IXBLUE

Contributor(s): TUCO, NAVREP, TSI, CIMNE, COMPASSIS, ULIM, BV, RINA, LLOYDS, DANAOS, ANEK,

FOINIKAS

Dissemination Level

PU Public x

PP Restricted to other program participants (including the Commission Services)

RE Restricted to a group specified by the consortium (including the Commission Services)

CO Confidential, only for members of the consortium (including the Commission Services)

D7.2 Engineering and

production of the

demonstrator

Document Information Table

Contract number: 723360

Project acronym: FIBRESHIP

Project Coordinator: TSI

Document Responsible Partner: IXBLUE iXblue

Deliverable Type: Demonstrator

Document Title: D7.2 Engineering and production of the demonstrator

Document ID: D7.2 Version: Third

Contractual Date of Delivery: 01/05/2019 Actual Date of Delivery: 16/07/2019

Filename: D7.2 Engineering and production of the demonstrator.docx

Status: Finished

Authoring & Approval

PREPARED BY

Author Date Modified Page/Sections Version Comments

TSI 08/07/2019 ALL V01 Creation of the document

IXBLUE 16/07/2019 Slight modifications V02 -

TSI 16/07/2019 Slight modifications V03 -

APPROVED BY

Name Role Partner Date

Document Manager Edouard Waldura Project Manager IXBLUE 16/07/2019

Document Approval Alfonso Jurado Project Coordinator TSI 16/07/2019


production of the

demonstrator

TABLE OF CONTENTS

EXECUTIVE SUMMARY ............................................................................................................................................. 6

1. DESIGN PROCESS.............................................................................................................................................. 7

1.1. BV RULES APPLICATION ................................................................................................................................. 7

1.2. BV SOFTWARE APPLICATION – MARS2000 - COMPOSEIT ................................................................................... 8

1.3. SCANTLING, LAMINATES DESIGN ................................................................................................................... 10

1.4. STRUCTURE DESIGN, 3D MODEL .................................................................................................................... 12

2. BUILDING PROCESS ........................................................................................................................................ 16

2.1. SCHEME OF THE MANUFACTURING PROCESS .................................................................................................... 16

2.2. REAL CONSTRUCTION PROCESS OF THE DEMONSTRATOR .................................................................................... 19

2.2.1. MOULD PHASE ...................................................................................................................................... 19

2.2.1. STRUCTURE INTEGRATION PHASE .............................................................................................................. 23

2.2.1. SPECIFIC FEATURES ................................................................................................................................. 26

2.3. FIBRESHIP DEMONSTRATOR FINISHED .......................................................................................................... 30

3. DEMONSTRATOR PRESENTATION DURING FIBRESHIP 2ND WORKSHOP ......................................................... 32

4. CONCLUSIONS ................................................................................................................................................ 37


production of the

demonstrator

LIST OF FIGURES

Figure 1 – FIBRESHIP Structure Calculations Through BV Rules – NR600 & NR546 and software used ................... 7

Figure 2 – Mars2000 - First Approach - Global loading, Deformation Epsilon Estimation ....................................... 8

Figure 3 – ComposeIT - First Laminate Approach .................................................................................................... 9

Figure 4 – Mars2000 - Global Loading: Shear Deformation Gamma ........................................................................ 9

Figure 5 – ComposeIT - Methodology for Loading Combination of Global and Local Loads - Pressure load ......... 10

Figure 6 – ComposeIT - Methodology for Loading Combination of Global and Local Loads - local loads .............. 10

Figure 7 – ComposeIT - Methodology for Loading Combination of Global and Local Loads - Load Cases ............. 10

Figure 8 – Methodology for Loading Combination of Global and Local Loads - Loading for Global Loads Under in

Plane Loads ................................................................................................................................................... 11

Figure 9 – ComposeIT - Second Laminate Approach, the Structure Design and The Demonstrator Was Built with

This Specifications ......................................................................................................................................... 11

Figure 10 – MidShip Structure Drawing with Laminates Definitions, Scantling and Joinings ................................. 12

Figure 11 – WebFrame Structure Drawing with Laminates Definitions, Scantling and Joinings ............................ 12

Figure 12 –3D Model of the Demonstrator located in the Fishing Research Vessel ............................................. 13

Figure 13 –3D Model of the Demonstrator 1 ........................................................................................................ 13

Figure 14 –3D Model of the Demonstrator 2 ......................................................................................................... 14

Figure 15 –3D Model of the Demonstrator 3 ......................................................................................................... 14

Figure 16 –3D view and plan view of accommodation spaces on auxiliary deck (upper deck of demonstrator) ... 15

Figure 17 –Manufacture Process, One Block Hull Structure Mould - First Step ..................................................... 16

Figure 18 –Manufacture Process, Principal Structure Definition for One Block – Intermediate Step Over the

Mould ............................................................................................................................................................ 16

Figure 19 –Manufacture Process, Blocks Connection – Intermediate Step Without Mould .................................. 17

Figure 20 –Manufacture Process, Inner Structure Inclusion .................................................................................. 17

Figure 21 –Manufacture Process, Demonstrator Assembly ................................................................................... 18

Figure 22 –Mould Building - Most Efficient Cutting Lines for Moulds and Low-Cost Mould Selection. ................. 19

Figure 23 –Mould Building ..................................................................................................................................... 19

Figure 24 –Hull Lamination - Big Thickness “Fire Resistant” System (30 plies of 1200g/m²) ................................. 20

Figure 25 –Hull Lamination - Big Thickness “Fire Resistant” System ...................................................................... 20

Figure 26 –Hull Lamination - Hull Infusion/Vacuum & Resin Reactivity Adjustment ............................................. 21

Figure 27 - Diagram explaining vacuum infusion with bagging film ....................................................................... 21

Figure 28 - Production of bulkhead and stiffeners for 3 months ........................................................................... 22


production of the

demonstrator

Figure 29 - Production of I-beams for 3 months. I-beams are lighter and smaller than full composite beams for

the same strength ......................................................................................................................................... 22

Figure 30 –Main Structure Construction – Girders & WebFrames assembled by hand lamination. ...................... 23

Figure 31 – First and Second Semi-Blocks Unmoulded .......................................................................................... 23

Figure 32 –Semi-Blocks Connection, Over lamination between both hull skins .................................................... 24

Figure 33 - Scarf production principle for connection ........................................................................................... 24

Figure 34 – Semi-Blocks Connection, Waiting for Principal Structure .................................................................... 25

Figure 35 – Addition of Bottom Principal Structure, Girders & WebFrames .......................................................... 25

Figure 36 – Inner Structure Inclusion ..................................................................................................................... 26

Figure 37 – Junction Details, Pillar Connection Between Double Bottom and Aux Deck ....................................... 26

Figure 38 – Junction Details, Pillar Connection Deck Support Design. In order to support the load transfer, the

base composite core is made with plywood instead of foam. ...................................................................... 27

Figure 39 – Demonstrator samples: Pipe penetration, Fire insulation, Cable trays supports ................................ 27

Figure 40 – Demonstrator samples: Handrails ....................................................................................................... 28

Figure 41 – Demonstrator samples: Waterproof door. The door frame is bolted on the bulkhead which is

reinforced to support the compression strength .......................................................................................... 28

Figure 42 – Demonstrator samples: Inner hole with windows .............................................................................. 29

Figure 43 – Demonstrator samples: Screwed porthole ......................................................................................... 29

Figure 44 – Demonstrator finished 1 ..................................................................................................................... 30

Figure 45 – Demonstrator finished 2 ..................................................................................................................... 31

Figure 46 – Demonstrator guided tour 1 ............................................................................................................... 32

Figure 47 –Demonstrator guided tour 2: presentation of the building process inside the demonstrator ............. 33

Figure 48 –Demonstrator guided tour 3 ................................................................................................................ 34





Figure 53 –Demonstrator guided tour 8: Group photo .......................................................................................... 36


production of the

demonstrator

LIST OF TABLES

Table 1 – FIBRESHIP Structure Calculations Through BV Rules – NR600 & NR546 Application ............................... 7

Table 2 – FIBRESHIP Structure Calculations Through BV Rules – NR600 & NR546 Application - Follow-Up ............ 8


production of the

demonstrator

EXECUTIVE SUMMARY

This document shows the steps followed in the design and building of the most representative milestone

of the FIBRESHIP project: the FIBRESHIP demonstrator.

The demonstrator presented is a full-scale ship block of a fishing research vessel (FRV) of 85m-length

fully in composites. It has been designed by TSI with the advice of BV and built by iXblue in its facilities

in La Ciotat. This demonstrator is of approximately 11 x 11 x 8.6 meters and 20 tons built in different

sorts of composite materials depending on the structural elements in question, in which the results of

the developed studies so far are verified and where the final tests will be carried out to confirm the

feasibility of the developments of the project. The demonstrator attempts to show a mixed block,

considering a engine room design on the bottom deck and some accommodation spaces on the auxiliary

deck (upper deck).

As a research, development and innovation project, it has been necessary to carry out a specific design

out of the ordinary, relying on experts of the several applied areas such as materials, joining, rules,

design, manufacturing and production procedures among others. This has been possible with the

support of the whole Consortium of FIBRESHIP.

Structural calculation, trade-offs reached, followed methodology and other technical results according

to the objectives of T4.1.3 (WP4) and T7.2 (WP7) are described in deliverable D4.3.

This document attempts to summarize and illustrate the entire process followed by the partners in the

design and construction by means of photos, including a time-lapse video of the building procedure as

well as the promotional video of the demonstrator presentation during the Progress Meeting 6 of the

FIBRESHIP project.


production of the

demonstrator

1. DESIGN PROCESS

1.1. BV Rules application

Figure 1 – FIBRESHIP Structure Calculations Through BV Rules – NR600 & NR546 and software used

Table 1 – FIBRESHIP Structure Calculations Through BV Rules – NR600 & NR546 Application


production of the

demonstrator

Table 2 – FIBRESHIP Structure Calculations Through BV Rules – NR600 & NR546 Application - Follow-Up

1.2. BV Software application – Mars2000 - ComposeIT

Figure 2 – Mars2000 - First Approach - Global loading, Deformation Epsilon Estimation


production of the

demonstrator

Figure 3 – ComposeIT - First Laminate Approach

Figure 4 – Mars2000 - Global Loading: Shear Deformation Gamma


production of the

demonstrator

1.3. Scantling, Laminates Design

Figure 5 – ComposeIT - Methodology for Loading Combination of Global and Local Loads - Pressure load

Figure 6 – ComposeIT - Methodology for Loading Combination of Global and Local Loads - local loads

Figure 7 – ComposeIT - Methodology for Loading Combination of Global and Local Loads - Load Cases


production of the

demonstrator

Figure 8 – Methodology for Loading Combination of Global and Local Loads - Loading for Global Loads Under in Plane Loads

Figure 9 – ComposeIT - Second Laminate Approach, the Structure Design and The Demonstrator Was Built with This Specifications


production of the

demonstrator

1.4. Structure design, 3D model

Figure 10 – MidShip Structure Drawing with Laminates Definitions, Scantling and Joinings

Figure 11 – WebFrame Structure Drawing with Laminates Definitions, Scantling and Joinings


production of the

demonstrator

Figure 12 –3D Model of the Demonstrator located in the Fishing Research Vessel

Figure 13 –3D Model of the Demonstrator 1


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demonstrator




production of the

demonstrator

Figure 16 –3D view and plan view of accommodation spaces on auxiliary deck (upper deck of demonstrator)


production of the

demonstrator

2. BUILDING PROCESS

2.1. Scheme of the manufacturing process

Figure 17 –Manufacture Process, One Block Hull Structure Mould - First Step

Figure 18 –Manufacture Process, Principal Structure Definition for One Block – Intermediate Step Over the Mould


production of the

demonstrator

Figure 19 –Manufacture Process, Blocks Connection – Intermediate Step Without Mould

Figure 20 –Manufacture Process, Inner Structure Inclusion


production of the

demonstrator

Figure 21 –Manufacture Process, Demonstrator Assembly


production of the

demonstrator

2.2. Real construction process of the demonstrator

Demonstrator Construction timelapse video: https://www.youtube.com/watch?v=iO9S1uSPehg&t=4s

2.2.1. Mould Phase

Figure 22 –Mould Building - Most Efficient Cutting Lines for Moulds and Low-Cost Mould Selection.

Chipboard main structure made by a CNC controlled machining and coated with plywood.

Figure 23 –Mould Building


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demonstrator

Figure 24 –Hull Lamination - Big Thickness “Fire Resistant” System (30 plies of 1200g/m²)

Before that, application of a release agent on the mould, 800µm of gel coat finish and a small thickness of laminated composite

Figure 25 –Hull Lamination - Big Thickness “Fire Resistant” System


production of the

demonstrator

Figure 26 –Hull Lamination - Hull Infusion/Vacuum & Resin Reactivity Adjustment

Figure 27 - Diagram explaining vacuum infusion with bagging film


production of the

demonstrator

Figure 28 - Production of bulkhead and stiffeners for 3 months

Figure 29 - Production of I-beams for 3 months. I-beams are lighter and smaller than full composite beams for the same strength


production of the

demonstrator

Figure 30 –Main Structure Construction – Girders & WebFrames assembled by hand lamination.

2.2.1. Structure Integration Phase

Figure 31 – First and Second Semi-Blocks Unmoulded


production of the

demonstrator

Figure 32 –Semi-Blocks Connection, Over lamination between both hull skins

Figure 33 - Scarf production principle for connection


production of the

demonstrator

Figure 34 – Semi-Blocks Connection, Waiting for Principal Structure

Figure 35 – Addition of Bottom Principal Structure, Girders & WebFrames


production of the

demonstrator

Figure 36 – Inner Structure Inclusion

2.2.1. Specific Features

Figure 37 – Junction Details, Pillar Connection Between Double Bottom and Aux Deck


production of the

demonstrator

Figure 38 – Junction Details, Pillar Connection Deck Support Design. In order to support the load transfer, the base composite core is

made with plywood instead of foam.

Figure 39 – Demonstrator samples: Pipe penetration, Fire insulation, Cable trays supports


production of the

demonstrator

Figure 40 – Demonstrator samples: Handrails

Figure 41 – Demonstrator samples: Waterproof door. The door frame is bolted on the bulkhead which is reinforced to support the

compression strength


production of the

demonstrator

Figure 42 – Demonstrator samples: Inner hole with windows

Figure 43 – Demonstrator samples: Screwed porthole


production of the

demonstrator

2.3. FIBRESHIP Demonstrator finished

Figure 44 – Demonstrator finished 1


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demonstrator

Figure 45 – Demonstrator finished 2


production of the

demonstrator

3. DEMONSTRATOR PRESENTATION DURING FIBRESHIP 2ND WORKSHOP

Demonstrator presentation video: https://www.youtube.com/watch?v=IW5KCJFRs9s

Summary of 2° Workshop in La Ciotat: http://www.fibreship.eu/fibreship-2nd-public-workshop/

Figure 46 – Demonstrator guided tour 1


production of the

demonstrator

Figure 47 –Demonstrator guided tour 2: presentation of the building process inside the demonstrator


production of the

demonstrator

Figure 48 –Demonstrator guided tour 3



production of the

demonstrator




production of the

demonstrator


Figure 53 –Demonstrator guided tour 8: Group photo


production of the

demonstrator

4. CONCLUSIONS

This document shows the FIBRESHIP demonstrator, a ship block fully in composites. It represents the

most important milestone of the project because provides the feasibility of this sort of structures for

vessels of large length. In this case, it has been designed a ship block of a FRV of 85 m in length, being

a modification of the FRV structural design due to budget issues and space capacity of iXblue facilities.

Throughout the process, several findings have been reached to improve the manufacturing system. All

of them are in deliverable D5.2 (WP5), nevertheless, below are summarized some of them:

1. A production method has been identified and qualified, which suits the materials and

designs developed in FIBRESHIP.

2. It has been identified the difficulty of reusing moulds. Because of that, low-cost mould

development must be considered for future projects.

3. Future advances in terms of automation processes should be developed for large composite

shipbuilding activities, in order to decrease manufacture costs.

4. For this sort of technology for large-length vessels, it is needed an adaptation of shipyards:

a) From existing large steel shipyards to composite shipyards.

b) From small composite shipyards to large composite shipyards.

c) From small composite shipyards sub-contracting parts/blocks to large shipyards.

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