Shape - Gurit

Markets: Marine
CrossiNG over To CopeNhaGeN’s
opera Now saves 50% eNerGy
The new Opera House offering spectacular views over the Renaissance city is a
prime attraction of Copenhagen. Opera goers, tourists and residents crossing the
harbour from Nyhavn now embark on a passenger and bicycle ferry built with Gurit
composite materials. With displacement halved at constant waterline length, Arriva 3
not only features a very short build time and low maintenance costs but also saves
approximately 50% of fuel compared with traditional vessels.
Die aus Verbundwerkstoffen gebaute neue Fähre
verkehrt in Kopenhagen zwischen Nyhavn und
dem Opernhaus und braucht dafür 50% weniger
Triebstoff.
往返于新港Nyhavn和哥本哈根歌剧院的新渡
轮,是用复合材料建成的,建成后的渡轮节
约燃料超过50%。
The Baltec Shipyard in Lübeck, Germany, is specializing in building
high-strength, fuel-efficient vessels using advanced composite materials.
Baltec and s p, the marine business of Gurit, have been working
together for several years. Having used s p’s engineering and
materials successfully in previous projects, Baltec drew again on
our expertise for its latest project, a monohull double-ender passenger
ferryboat for inland waterways. The Arriva 3 ferry is specifically
designed for quick to-and-fro service for up to 100 passengers and
bicycles between Nyhavn and the Opera House. The crossing to the
spectacular theatre building inaugurated in 2000 offering sweeping
views of Renaissance Copenhagen only takes five minutes.
iMpressive fuel saviNGs
Arriva 3 was constructed with reliable materials certified for a lightweight
composite design and build, allowing a significant reduction
of the overall weight while ensuring most demanding performance
criteria. Halving the ship’s displacement at constant waterline length
reduced the necessary engine input also by half. As a consequence,
Arriva 3 only consumes about 50% of the fuel similar vessels built in
aluminium would typically use. And, in addition to remaining strong
and robust, the tough epoxy surface of Arriva 3 keeps regular maintenance
costs at a low.
CoMplyiNG wiTh MosT deMaNdiNG
fire resisTaNCe requireMeNTs
Baltec chose s p’s s t 70fr Fire Retardant s p r i n t ® E-Glass prepreg
materials for all sandwich panel laminates for this commercial craft
that meets the most stringent industry standards: s t 70fr, part of
our s p r i n t ® product range, not only passed the complex German fire
According to Baltec, an aluminium construction needs four times
more stringers than a composite sandwich construction. Considering
that aluminium welding of 1m takes about three times longer than
composite bonding, approximately 400 additional hours are required
to build a comparable vessel in aluminium. The table illustrates the
time savings for one of Baltec’s previous ship designs.
While this calculation highlights the considerable time savings, it does
not even take into account the additional isolation process required
for all aluminium outer shell surfaces. Composite sandwich constructions
are by definition self-isolating. Time in maintenance using adhesive
welding is another huge time saver.
resistance standard d i n4102/b1 in a recent s p build, the same res-
in system was also passed by Baltec through the International Maritime
Organisation (i m o) ftp Code part 5 requirements in conjunction
with a fire retardant (intumescent) coating for the construction of
Arriva 3. The s t 70fr-b l s p r i n t ® system proved vital for Baltec’s overall
process control and the production of large composite panels of
approximately 30m 2 each.
siGNifiCaNTly lower Build TiMes
Baltec’s fillet joint bonding solution – a technique comparable to
welding steel plates together – uses a combination of two s p adhesive
systems. A fillet bondline of Spabond 340 was applied to join the
sandwich panels. This structural adhesive features high strength and
sag resistance qualities which are fundamental to this part of the process.
Spabond 540p b was used to bond stainless steel and composite
parts together; its high elongation at break is a necessary property
to cope with the diverse thermal movement characteristics of the
different materials combined. Spabond 340lv was applied for gluing
all panels, stringers, bulkheads, longitudinals, transversals and deck
parts together. Using a special mixing and dispensing machine made
it possible to apply the adhesive at the same time as forming the fillet
– a much faster method in comparison with metal-welding.
six MoNThs froM keelplaTe To full fiNish
Arriva 3 is a fitting example to demonstrate that using adhesive welding
can result in a short build time of just six months for a small team
of 8 and 12 people. Starting in February, the s p and Baltec shipyard
teams finished the build of this 32.7m x 7m ferry well in time for its
operation in the Port of Copenhagen begining in August 2009.
Preparation of single parts/cutting
and kitting
12 shape
The Gurit Magazine 05_2009 13
Adhesive
welding
Aluminium
welding
10% 10%
Part positioning and adjusting 20% 20%
Welding of hull panels 10% 30%
Welding of bulkheads/stringers 10% 75%
Use of positioning equipment 20% 20%
Finish 30% 30%
t o ta l 100% 185%