From 700kg to 76kg: How Composite Engineering Solved a Real Structural Challenge
- Jul 23
- 5 min read
Updated: Jul 24
Reducing a mast's weight from 700kg to just 76kg didn't simply save weight. It eliminated structural damage, replaced a problematic hydraulic system and transformed a daily operation aboard an 85-metre luxury passenger vessel.
When people think about advanced composites, they often picture high performance applications such as racing yachts and aerospace.
While composites certainly excel in these fields, they also do exceptionally well in solving practical engineering problems that traditional materials struggle to overcome - as demonstrated in a recent project completed by Triac Composites.
Working with an 85-metre (279ft), five-deck luxury passenger vessel operating on the Mekong River through Vietnam and Cambodia, our brief was to replace a heavy steel mast with a composite alternative. What initially appeared to be a straightforward weight-saving exercise ultimately became a complete engineering solution that improved safety, simplified operations and reduced maintenance costs.
The Challenge
Operating on the Mekong River presents a unique navigational challenge.
The vessel must regularly pass beneath low bridges, requiring the main mast to be raised and lowered multiple times during normal operations.
The original steel mast weighed approximately 700kg. That weight created problems well beyond the mast itself.
A hydraulic ram had been installed to raise and lower the mast, but the loads generated by lifting such a heavy structure exceeded what the wheelhouse roof - the deck through which the lifting forces were transmitted - could comfortably withstand. Over time, the repeated loading began causing structural damage.
To reduce the stress on the vessel, crew members were required to manually assist every lifting and lowering operation.
The hydraulic system also suffered from oil leaks, increasing maintenance requirements and creating an undesirable situation aboard a luxury passenger vessel.
The objective wasn't to replace a component... It was to eliminate the cause of the problems that that component had created.
Rethinking the Problem
Rather than replacing steel with more steel and strengthening the roof of the wheelhouse, the engineering teams (see footnote below on engineering) from the client and Triac worked together.
If the mast could be made dramatically lighter while maintaining the required structural performance, the entire lifting system could be simplified.
That meant solving multiple operational problems with a single engineering solution.
The Composite Solution
Triac designed and manufactured a completely new mast using E-glass reinforcement over a structural PVC foam core. The laminate was manufactured using the vacuum infusion process.
Vacuum infusion allows resin to be drawn evenly through the laminate under vacuum pressure which in turn produces an exceptionally consistent composite structure (ie an optimal fibre-to-resin ratio). The result is a component that delivers outstanding strength by elimiating internal voids at the lowest possible weight.
The Results
The finished mast which is 3.8 metres high and 2.5 metres wide weighs just 76kg.
Component | Weight |
Original steel mast | ~700kg |
Triac composite mast | 76kg |
Weight reduction | 624kg (89%) |
Benefits Beyond Weight
Reducing the mast's weight by more than 600kg transformed far more than the mast itself. By replacing a 700kg steel structure with a 76kg composite mast, the project was able to deliver:
A simpler lifting system: The large hydraulic ram was replaced with a compact electric actuator that raises and lowers the mast smoothly, quietly and with minimal effort.
Reduced structural loads: Dramatically lower forces are transmitted through the lifting mechanism, eliminating the structural loading that had previously damaged the wheelhouse roof.
Improved crew safety and efficiency: Crew members no longer need to manually assist every lifting operation, making bridge transits quicker, safer and less labour-intensive.
Lower maintenance: The elimination of the hydraulic system removed persistent oil leaks, while the corrosion-resistant composite mast requires far less maintenance than the original steel structure. Particularly important aboard a 5 Star luxury vessel.
Corrosion-free construction: Unlike steel, composite materials do not rust or corrode, preserving both appearance and structural integrity in the demanding environment of the Mekong River.
Lower lifetime operating costs: Fewer moving parts, reduced maintenance and the elimination of hydraulic servicing contribute to lower operating costs throughout the vessel's service life.
Improved electrical insulation: Glass fibre is naturally non-conductive, providing an additional safety benefit for a tall structure operating in an environment where lightning storms are common. It also reduces the risk of electrical faults should cables chafe during repeated mast movements.
What began as a lighter mast became a smarter engineering solution that improved the performance, reliability and maintainability of the entire system.
Click to play video above. Raising and lowering of the new 76kg composite mast.
An Ongoing Relationship
This wasn't Triac's first project for the vessel.
Previously, we designed and manufactured a custom composite gangplank to replace a traditional metal structure.
The result was another significant reduction in weight, making the gangplank much easier for the crew to deploy while eliminating corrosion and reducing maintenance.
Although the applications are different, the engineering philosophy remains the same: solve operational problems by designing smarter composite structures.
Where Composite Structures Deliver the Greatest Benefits
Projects like this illustrate an important point.
The real value of composite engineering isn't simply replacing one material with another.
It's identifying where traditional materials have become the limiting factor and then rethinking the entire solution.
Across marine, industrial and commercial applications, steel and aluminium components are often heavier than they need to be. Excess weight can create knock-on effects throughout a system, increasing structural loads, (and in this case) requiring larger actuators, making equipment harder to handle and driving up maintenance costs.
By redesigning components in advanced composites, it's often possible to simplify the entire system rather than merely improving one part of it.
What Engineering Problem Are You Trying to Solve?
Every engineering challenge begins with a problem.
Whether you're dealing with excessive weight, corrosion, structural loading, difficult manual handling, high maintenance costs, or something else, advanced composites can often provide solutions that traditional materials of steel, aluminium and timber cannot.
At Triac Composites, we work with clients across the marine, industrial and commercial sectors to design and manufacture structural composite solutions that improve performance, simplify systems and reduce lifetime operating costs.
Talk to Triac Composites
If you're replacing an existing steel, aluminium or timber structure, or developing something entirely new, we'd welcome the opportunity to discuss your project.
General Enquiries
Confidential Enquiries or Business Development Discussions
Phil Johns, Marketing & Business Development Director
Sometimes the best engineering solution isn't a better design; it's a better material.
Let's explore what's possible with advanced composites.
* A Note on Engineering Partnerships at Triac Composites
While this article highlights the structural and engineering advantages of our composite solutions, it is important to clarify Triac Composites' primary role.
At our core, we are expert builders and manufacturers. Although we possess valuable in-house engineering expertise, we achieve these remarkable results by working extremely closely with specialist engineers and naval architects.
For our own proprietary builds, we proudly partner with the globally renowned firm Morrelli & Melvin, and for custom client projects, we collaborate seamlessly with the engineers our customers have engaged.
Should a client come to us with a concept but no formal engineering support, we are always happy to recommend highly qualified professionals to ensure the project is expertly designed before we bring it to life on the factory floor.
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