Innovative New Ship Cladding Creates Jobs and Reduces Emissions

Source: Sally Wood

LEFT: CBG Systems has been a manufacturer of passive fire protection systems for the past 30 years, and their panelling is currently found on 90 per cent of the world’s high-speed ferries. MIDDLE: Senior experimental scientist, Mel Dell’Olio, holds up a sample of the new and improved RAC Plus fire-resistant panel. RIGHT: The RAC Plus panels are fully noncombustible and remain structurally strong after exposure to extreme heat. ©FLOODLIGHT MEDIA

A new lightweight, fire-resistant cladding, that can withstand temperatures of more than 1,000°C is set to change the face of ships around the world.

The material has been developed by Australia’s national science agency, CSIRO, in collaboration with Tasmanian small business, CBG Systems, and has already been installed on two new ships and used to replace cladding on another. The prototype panelling, called Rapid Access Composite (RAC) Plus, is the first of its kind in the world that uses a thermal protective coating, and remains structurally stronger than conventional fire protection coatings. The innovative panels are also reversible and can repel water, potentially doubling their service life. The current design is specific for high speed aluminium ships, but the composite has the potential to be modified for construction products. Weighing about half as much as traditional metal cladding, the resulting reduction in fuel consumption will lower carbon emissions, leading to greener ships across the globe, as well as enhancing overall operational efficiencies. The new technology was supported through several Federal Government programs, and has created new jobs and increased international trade to Hobart. CSIRO Chief Executive, Dr Larry Marshall, said the partnership showed the power of science to solve real world challenges. “By working side by side with industry, innovative science and technology creates new value and growth for Australian businesses to grow our way back from the current crisis,” Dr Marshall said. “This home-grown Aussie innovation has enabled CBG Systems to become an advanced manufacturer of globallycompetitive marine insulation products and services, which is now bringing in valuable export dollars from around the world.” CSIRO Senior Experimental Scientist, Mel Dell’Olio, spent four months at CBG in Hobart, training and upskilling employees in advanced manufacturing techniques and assisting with the commercialisation process. During that time, the team manufactured 2,500 insulation panels, which are now being built into new ships, internationally, all meeting the relevant fire standard tests for the marine industry, and offering at least 60 minutes of fire protection. Dell’Olio said CBG Systems’ long history of research and development in marine fire protection had been demonstrated again through the innovative RAC Plus. “To be filling production orders, within two years of the first project meeting, demonstrates how Australian SME manufacturers can benefit from positive research partnerships,” Dell’Olio said. Managing Director of CBG, Javier Herbon, said that CSIRO had decades of experience and expertise in developing advanced new materials with special properties for industry, such as fire resistance, durability and protection. “Being able to access the wealth of scientific knowledge and innovation within CSIRO has been an incredibly enriching experience for everyone at CBG Systems,” Herbon said. “With three ships already ordered, and two ships complete, CBG systems has hired six new roles, with partners and suppliers also increasing their staff as a result.” “This project shows how innovations from CSIRO can help Australian businesses create manufacturing jobs,” Herbon added. CBG Systems has lodged their own patent on RAC Plus, and recent fire tests indicate the new and improved panels, with greater durability and fire-resistance, can be used on steel ships and aluminium high-speed crafts. There are also potential applications in aerospace for battery enclosures, and also the civil construction industry, enabling CBG to expand into new markets. CBG Systems has been a leading innovator in marine insulation, communications and lightweight passive fire protection, for over 30 years. Their products strike the balance between saving lives and saving money, with military operators worldwide recognising CBG for their excellence – including the US Navy.