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Incat, a distinguished name in the shipbuilding industry, has been redefining maritime engineering since its inception in 1978. Incat specialises in high-speed, lightweight aluminium passenger vehicle ferries and has become synonymous with innovation and sustainability.
Using aluminium to construct its vessels is integral to Incat’s design philosophy and operational strategy, and the business has had a long-standing partnership with Capral Aluminium.
Robert Clifford founded Incat as a family business with small ferries across Hobart’s Derwent River. This modest beginning ignited a passion for innovation, leading to the development of some of the world’s largest passenger catamarans. Today, Incat’s vessels are common across many continents, including Europe, the Americas, and Asia. Stephen Casey, CEO of Incat, explains, “From really small, humble beginnings as a family business, Incat vessels now are all around the world,” highlighting the company’s expansive reach.
Based in Derwent Park, Hobart, Incat boasts the largest covered shipyard in the southern hemisphere. The facility, comprising five large production halls, is strategically located on the waterfront of Prince of Wales Bay, facilitating the seamless launch and sea trials of its vessels.
Incat is a business committed to innovation and sustainability, which in part has driven a strong preference for aluminium. Aluminium brings many benefits to the marine sector, one of the most significant being its lightweight, which transitions into efficiencies in speed when used in hull construction. Aluminium is approximately one-third the weight of steel, significantly reducing vessels’ overall mass. This weight reduction is crucial for achieving the high speeds that Incat’s catamarans are known for. “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,” explains Stephen Casey, CEO of Incat. This characteristic is especially beneficial for ferry operators who require fast turnaround times and efficient operations over short sea routes.
For much the same reason, aluminium is now pivotal in the company’s shift towards battery-electric propulsion systems. This transition to electric power is part of Incat’s broader strategy to build zero-emission vessels and reduce the maritime sector’s carbon footprint. The ability to accommodate more batteries without compromising speed or efficiency makes aluminium an ideal material for these cutting-edge, eco-friendly ships.
CEO Stephen Casey emphasises, “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.”
Hull 96, currently under construction, epitomises this spirit. At 130 meters long, it is the largest ferry Incat has ever built and will be the world’s largest battery-electric vessel upon completion. “We’ve designed this vessel to be 100% battery electric powered,” says Casey, highlighting the company’s commitment to sustainability and technological advancement.
A crucial aspect of Incat’s success is its long-standing partnership with Capral, Australia’s leading supplier of aluminium, which underscored the importance of high-quality materials in its shipbuilding process. Capral provides marine-grade aluminium alloys, specifically 5083 and 5383, which are essential for the structural integrity and performance of Incat’s vessels. These alloys offer superior strength and are certified by DNV, ensuring they meet rigorous international standards. “All our plate and extrusion is certified by DNV as an independent third party,” McCourt states, emphasising the reliability and safety of the materials used.
Capral’s ability to supply high-quality aluminium tailored to Incat’s specific needs further cements this partnership. Capral holds proprietary dies developed by Incat, producing unique extrusions essential for various ship components. “Capral basically will hold stock for us within their network, without us necessarily having to bring it in until we need it,” McCourt adds, highlighting this collaboration’s logistical benefits.
Aluminium’s corrosion resistance and longevity contribute to the high quality and reliability of Incat’s vessels. Michael McCourt, COO of Incat, elaborates on this, noting that the company’s ships, many over 40 years old, continue to perform reliably due to the high-quality aluminium used in their construction. “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,” says McCourt.
The design benefits of aluminium extend beyond speed and durability to passenger comfort. Aluminium enables the creation of Incats trademark wave-piercing catamarans, significantly improving ride quality by slicing through waves rather than slamming into them. This results in smoother and more comfortable passenger crossings, a crucial selling point for ferry operators.
Incat’s investment in its workforce is another cornerstone of its success. The company employs many skilled professionals, from naval architects and engineers to welders and electricians. Casey highlights, “We want to train Tasmanians here to have great skills… They can be trained from the start of their career and have a great career here with Incat.”
As Incat approaches its 50th anniversary, the company shows no signs of slowing down. The focus on electrification and sustainability positions Incat as a leader in the maritime industry’s shift towards greener technologies. Casey envisions a future where Incat’s innovations continue to set global standards: “We know there’s a huge fleet across the world that needs to find a net zero carbon emission solution, and we have it here at Incat.”
Incat’s journey from a small family business to a global pioneer in shipbuilding is a testament to its unwavering commitment to innovation, quality, and sustainability. With partners like Capral, Incat is poised to navigate the future of maritime transport, crafting vessels that not only meet but exceed the industry’s evolving demands.
