Incat is a globally renowned shipbuilder based in Hobart, Tasmania. With over four decades of experience, Incat specialises in high-speed, lightweight aluminium vessels that serve commercial and passenger transport needs worldwide.
Their latest and most ambitious project Hull 096 is a bold move toward sustainability. Incat configured the vessel to operate entirely on battery-electric propulsion, a world-first at this scale.
At 130 metres long, Hull 096 can carry over 2000 passengers and 225 vehicles. Equipped with a 40 MWh energy storage system, Hull 096 is the largest battery-electric passenger ferry ever built. This represents a major step forward in zero-emission transport and sustainable shipbuilding.
THE CHALLENGE
Building a vessel of this scale and complexity required precision at every stage. For Incat, quality means consistency, accuracy, and attention to detail. Every weld contributes to the structural integrity of the ship, making reliable inputs critical.
“We rely on suppliers who can consistently support our work with dependable products that meet the standards required for marine-grade aluminium fabrication”, says Incat CEO Stephen Casey.
Marine-grade aluminium fabrication demands high-quality shielding gases to ensure clean, strong welds. Any interruption in their supply impacts productivity and the team’s workflow, so Incat needed support from a supplier who could deliver dependable gas solutions without any compromises.
OUR SOLUTION
Coregas worked with Incat to supply welding gases to suit the high-performance needs of aluminium shipbuilding. Our role was to ensure consistent delivery, maintain product quality, and provide technical support where needed.
We provided:
- • Optimised welding gas solutions for the best outcomes in aluminium welding performance
• A reliable supply chain to ensure production was on schedule
• High-purity gases that supported weld integrity and reduced rework
• Thorough communication and technical expertise from our support team
Mr. Casey went on to say, “Coregas has been easy to work with. Their supply has been consistent, and communication has been straightforward, which helps keep things running smoothly on our end.”
SKILLS, PRODUCT & TECHNOLOGY
Hull 096 is a showcase of advanced engineering and innovation. The Incat team combines traditional craftsmanship with innovative technology, continually refining lightweight vessel design and integrating systems that support cleaner propulsion.
Welding is a fast-changing landscape, and Incat is adopting new techniques and equipment to improve efficiency and quality. Coregas’ high-performance gases complement these innovations, enabling precision welding for marine-grade aluminium and supporting the structural integrity of such a significant undertaking in vessel size and innovation.
Incat also invests heavily in skills development. Apprentices and tradespeople are trained to follow strict processes and maintain attention to detail, ensuring every weld meets engineering standards. This disciplined approach makes projects like Hull 096 possible.
THE OUTCOMES
Hull 096 was successfully launched on May 2, 2025, marking a historic moment in global shipbuilding. The vessel will soon begin zero-emission operations across the Rio de la Plata, redefining sustainable maritime transport.
This collaboration demonstrates how Coregas supports innovation in large-scale manufacturing through dependable gas solutions. By ensuring quality and reliability, we helped Incat achieve its vision of building the world’s largest battery-electric ship — a project that puts Tasmania and Australia firmly on the global stage.
