Incat’s eco-voyage: Spearheading zero-emission ferries with Capral Aluminium

Founded by Robert Clifford, Incat Tasmania is a renowned Australian manufacturer of high-speed lightweight catamarans that has revolutionised maritime engineering. Incat specialises in high-speed, lightweight aluminium passenger vehicle ferries and is synonymous with innovation and sustainability. 

"The real focus has been on using aluminium because that gives us the lightweight product, which allows us to operate the vessels at a high speed. Our passion now is building the vessels for the future, which are going to meet the zero emissions and reduce the carbon footprint of the maritime sector around the world," added CEO Stephen Casey of Incat. 

Based in Derwent Park, Hobart, Incat boasts the largest covered shipyard in the southern hemisphere. This facility, which includes five large production halls, is strategically located on the waterfront of Prince of Wales Bay, facilitating seamless launches and sea trials of its vessels.

Incat's partnership with Capral

Their longstanding partnership with Capral Aluminium is crucial in this approach, Australia’s leading aluminium supplier, highlighting the importance of high-quality materials in shipbuilding. Capral supplies marine-grade aluminium alloys, specifically 5083 and 5383, crucial for the structural integrity and performance of Incat's vessels. These alloys provide exceptional strength and are certified by DNV, ensuring they meet stringent international standards.

The use of aluminium in their vessel construction is central to Incat's design philosophy and operational strategy. Incat is a company dedicated to innovation and sustainability, which has led to a strong preference for aluminium in its vessel construction. 

Capral's ability to supply high-quality aluminium tailored to Incat's specific needs further strengthens this partnership. Capral maintains proprietary dies developed by Incat, enabling the production of unique extrusions essential for various ship components.

About Hull 96

Hull 96, currently under construction, embodies this innovative spirit. At 130 meters long, it is the largest ferry Incat has ever built and will become the world's largest battery-electric vessel upon its completion.

The hull is segmented into eleven vented, watertight sections by transverse bulkheads. Within each hull, three compartments are designated explicitly as fuel oil tanks. These compartments feature reinforced end bulkheads and intermediate tank tops for added durability.

"Our hulls are 40 years old around the world, and you see the quality through and through. It's not just the workmanship from the people here at Incat, but it's the quality of our products, and that aluminium from Capral is a key ingredient to our vessels," stated Michael McCourt, COO of Incat. 

Aluminium's role in Incat's transition

Aluminium offers numerous advantages to the marine sector, the most notable being its lightweight nature, which enhances speed efficiency in hull construction. Being approximately one-third the steel weight, aluminium significantly reduces the overall mass of vessels. This weight reduction is essential for achieving the high speeds that Incat's catamarans are renowned for.

Similarly, aluminium plays a crucial role in Incat's transition to battery-electric propulsion systems. This shift to electric power aligns with Incat's broader strategy to develop zero-emission vessels and reduce the maritime sector's carbon footprint. Aluminium's lightweight nature allows for the accommodation of more batteries without compromising speed or efficiency, making it the ideal material for these advanced, eco-friendly ships.

The design benefits of aluminium go beyond speed and durability, enhancing passenger comfort as well. Aluminium allows for creating Incat's trademark wave-piercing catamarans, which improve ride quality by slicing through waves rather than slamming into them. This results in smoother, more comfortable crossings, a key selling point for ferry operators.