Going full circle?

Recently, Damen Shipyards Group has constructed a full-scale Circular Crew Cabin demonstrator. The 2.5 by 2.7 metre modularly designed cabin is the result of three years of intensive in-house research and development and collaboration across departments and with multiple suppliers.

Driven by sustainable ambition

Damen began the project in 2023 – stimulated by three main drivers – environmental regulations, increasing client demand for sustainable vessels and the group’s own sustainability ambitions.

The company chose to focus its efforts on a crew cabin for a number of reasons, explains project founder and Senior Research Engineer Renaud Gaudel. “We needed to start somewhere on the vessel and the materials used in crew cabins often have a high impact on the environmental footprint.”

Additionally, Renaud has a background in R&D of acoustics and vibration on board vessels. As such, he is familiar with interior areas and with the suppliers who provide the components for them.

Four pillars – a firm foundation

The project, he explains, has been built upon the four pillars of Define and Assess Circularity Baseline, Improve Circularity, Consequence and Design, and the final phase – the Demonstrator.

“The first step was to define what we mean by circularity. In the case of the crew cabin it meant that we use no virgin materials – everything should be either reused, remanufactured or recycled.”

Towards highest impact

In order to achieve the greatest impact, Damen set out to assess the baseline of a Commissioning Service Operations Vessel (CSOV) and an ASD Tug.

“The thinking here is that offshore vessels have a high number of crew cabins,” Renaud explains. “And, while workboats have less, we do construct a high number of such vessels.”

Following this, Renaud and his team began to consider the materials that would support the creation of a circular cabin.

“We started to look into what materials we might use – how we might limit virgin materials, and what components would last a long time, as well as how to ensure a more efficient disassembly at end of life.”

Collaborating with colleagues...

At this point, the project began to call upon considerable collaboration from colleagues from various Damen departments in a bid not only to develop a more circular crew cabin, but also one which was viable. One of those who then joined the project was Johan Vissers, Damen Workboats’ System Owner for Interior and Experience.

“For Damen, and for our department, a real trigger for becoming involved in this project was the opportunity to create an inviting environment – a place where crew can work and rest. For me, this is a primary focus for our next generation of vessels, and the Circular Crew Cabin is the first step. I think people are going to be pleasantly surprised by what they encounter.”

Renaud adds, “It’s been good to partner with Johan. I had the ambition to make the cabin as circular as possible, but through this cooperation, we have managed not only to achieve our circularity objectives, but also to provide our clients, colleagues and suppliers with a realistic glimpse into the future.”

Johan explains the process he applies to designing interior spaces, saying, “I try to be the person who will use the space. When I step onboard I’m looking at everything through the eyes of the captain and the crew. I ask myself questions such as ‘Would I be comfortable spending two weeks at a time here?’ ‘Am I happy with the view, the climate, the controls?’ The demonstrator crew cabin we have created is the result of this process.”

... and partners

At the same time, the project was supported by more than twenty suppliers – including both current and new Damen suppliers.

“Our current suppliers have done a great job over the years. However, frequently we were considering different materials, so we had to call upon new suppliers, too. In many cases, they have come together to find a suitable solution,” Renaud says.

Johan agrees, saying, “We call them suppliers, but honestly, they’re partners. The way they have stepped up to the challenge and the enthusiasm with which they have approached the project is commendable.”

Advancing circularity

As a result of the collaboration with suppliers and across Damen, the project has reached an advanced stage of circularity.

“The materials principles we are now bringing forward are green instead of grey and around 50% of them are ready for immediate implementation in production. We have also been able to develop a roadmap to increase circularity further going forward. I think we will quickly achieve 80% circularity, though there is still some way to go before we reach 100%.”

Many of the components in the demonstrator have not been used in a maritime environment before and therefore require class approval and certification. The greater challenges the Circular Crew Cabin faces, Renaud states, are cost and scalability. 

Creating scale, cutting costs

“It’s not that the principles are more complicated. It’s that the suppliers won’t immediately have the volume of demand required to offer the components at a competitive price. We will use the demonstrator to push for increased volumes, but not everything is in our hands.”

“The policy makers and public authorities also have a role to play,” adds Johan. “We have provided a solution, but it’s up to governments – at the European and national level – to open the doors. The grey products of today have to account more for the environmental damage, for example, by raising a tax on them. The revenue from these taxes could be put towards incentivising green solutions. That way, the demand will increase, the cost will come down and we can offer this to our clients.”

A time to celebrate

While this remains a challenge, now is a time for celebration, Johan continues.

“It’s a real achievement that we have managed to create this demonstrator in time for this year’s Damen Maritime Festival. I’m looking forward to visitors seeing it. I think they are going to be very positively surprised.”

The demonstrator was put together in the Atrium of Damen Shipyards Gorinchem by colleagues from the Timmerfabriek – Damen Shipyards Hardinxveld. In addition to the Maritime Festival, colleagues, suppliers and clients will be invited to visit in the coming months. It is, Renaud says, the successful culmination of the project.

“Our goal was not to create nice slides or write a nice report. It was to create a real, tangible crew cabin that people could experience for themselves. With this demonstrator, we have achieved what we set out to achieve. It’s been a real challenge, but with everyone’s commitment and hard work, we’ve made it happen. By having the materials in our hands and assembling the cabin, we have learned a lot. This is an important step towards increased circularity.”

A catalyst for what’s to come

It is, however, only the beginning of the story.

“We are already thinking of the following projects,” states Renaud. “For example, we are looking at the possibility of circular floating floors and, of course, the rest of the vessel has to be circular. This project is, in fact, only the catalyst for what is to come.”