Incat’s world beating Wave Piercing Catamarans are created through a production line system at the dedicated 70,000 m2 undercover facility. Up to six vessels can be handled simultaneously in two drydocks which includes the ability to house construction of larger vessels up to 150 metres in length. Like any thriving business, a core of dedicated and loyal staff can be found at the centre of Incat’s success. With high levels of job satisfaction, Incat ensures a low staff turnover rate and a skilled workflow where many team member's experience stretches back over two decades across a range of trades. Incat is proud to count the world’s finest skilled technicians amongst its workforce. High performance vessels require high quality welding and the training of welders, development of appropriate welding procedures, and advanced testing techniques are essential to Incat’s continued success. To that end Incat has developed a close relationship with the Hobart Institute of Technical and Further Education (TAFE) where training courses are directly matched to Incat construction needs. The purpose-built TAFE College of Aluminium Training has been constructed adjacent to the yard for even greater convenience. Plate Shop High-strength marine grade aluminium alloy, sourced in structural sections and plate from specialist suppliers in Australia, France and Switzerland, arrive at the plate shop where they are purpose cut using software proprietary to the cutting equipment on site. Nesting plans are generated to extract a useable part from every stock piece of material. To get the maximum efficiency from a cutting run sometimes means including parts that will not be required until the next vessel, but the team will fit in a part wherever the opportunity arises to reduce waste. Pre-Fabrication The Inches shed was constructed in 1989 along with the neighbouring McGregor shed to facilitate the building of Incat's early Wave Piercing Catamarans. Today the site is dedicated to the manufacturing of vessel components and it is to here that materials are delivered from the plate shop ready for pre-fabrication. At any one time a visitor to the yard is likely to witness modules under construction such as wave piercing bows, engine rooms and fuel tanks to name but a few. From liferaft cradles, trim tabs and safety rails to wheelhouses, hull sections, engine rooms, complex jet rooms and centre bows, these are all created within the Inches and McGregor pre-fabrications complex before being transported the short distance to the cavernous Coverdales and Wilsons assembly halls. The benefits of pre-fabrication are immense. Components can be rotated and by selecting orientation the number of down-hand welds can be increased which in turn shortens welding time. Bulk plating, where the longitudinal structure extrusions are welded to the shell plate, means that welding is only required at transverse frames when these units are lifted into position. Assembly In 1994 Incat established the world’s first large scale aluminium ship building production/assembly line. The resultant improvements in efficiency and product quality enabled the company to double its capacity and to pass on significant benefits to customers. Assembly is divided into three stages: Stage 1 – The aft frames are stood and the first plating takes place. Portals are stood and the sewage holding and water tanks are added. Cross bracing is added here and the vessel grows from the transom forward. Stage 2 – Having been rolled back into Stage 2 the jet rooms and bridging modules are added to the vessel. Work starts on the superstructure base while simultaneously the engine room is readied for its machinery. Pre-fabricated superstructure modules are lifted into position. The vessel continues to grow in this stage until it reaches approximately 600 tonnes at which point it is rolled back into the next stage of the shed, clearing the production line for the next hull. Stage 3 – The final move of the vessel before launching positions the ship in the dry dock. Work starts on closing-up the forward end of the ship and welding is completed. The unique Incat catamaran shape becomes recognisable as the wave piercers are fitted and the bottom is painted. With engines installed, painting completed and wheelhouse fitted the vessel is all but complete. Fitout The majority of fitout work is completed by the yard’s tradespersons in stage 3. Fitters, plumbers, electricians, electronics, fitout, hydraulics, pneumatic, painters and structural fire protection personnel all set about installing components and vessel systems. Incat’s Quality Assurance staff and the classification society DNV inspect the vessel and sign off on welding and works completed to their satisfaction. Launch With engines installed the vessel is ready for launching, once clear of the shed the radars and aerials are fitted and final commissioning of systems takes place. Builder’s trials and sea trials for the customer are completed and the vessel is ready for handover and delivery to her new home.