AWARDS 2024 | Best Small Fast Ferry – Sea Express III – SeaCat Ships
This small aluminium fast ferry was built in Thailand for an experienced tourism operator in the British Virgin Islands. A simple, rugged and versatile boat that is economical to both purchase and maintain.
It’s a “hose out” ship. With its characteristic high SeaCat Ships tunnel, she can comfortably operate at speed in the significant trade wind seas that are the norm in places like the BVI.
These impressively versatile and comparatively inexpensive vessels should be attractive to operators almost everywhere.
"The vessel stands out as a high-performance, passenger-friendly ferry designed to deliver a seamless travel experience in the US Caribbean," Paul Birgan, Director and Design Manager at SeaCat Ships, told Baird Maritime.
"Several key features make it special. With a top speed of 27 to 28 knots and a cruising speed of 23 knots, it ensures fast and efficient transportation, reducing travel time while maintaining fuel efficiency."
Birgan added that the air-conditioned main cabin provides a cool, comfortable space for 66 passengers, and that the open-air upper deck offers seating for 34 passengers, allowing travelers to enjoy fresh sea breezes and scenic views.
"The vessel was designed with smooth sailing in mind, ensuring a comfortable ride even in rough sea conditions," said Birgan. "It is fully compliant with US Coast Guard Subchapter T regulations, ensuring the highest levels of safety and reliability, whilst inspection by official regulators guarantee operational integrity and passenger security."
Sea Express III was engineered specifically for the US Caribbean, and so it can handle the region’s unique sea conditions while offering a smooth and enjoyable ride. In Birgan's view, the combination of speed, comfort, and safety makes the vessel ideal for transporting both commuters and tourists.
Like any advanced vessel project, the design and construction of Sea Express III came with its own set of challenges. However, each step provided the SeaCat Ships team with valuable insights that helped refine the final product.
"Ensuring full compliance with stringent Subchapter T regulations required careful planning and close coordination with inspectors," Birgan told Baird Maritime. "While the process added complexity, it reinforced the importance of early engagement with regulatory bodies to streamline approvals.
Designing a ferry that could reach 27 to 28 knots while maintaining fuel efficiency and passenger comfort required precise hull optimisation. Birgan explained that extensive testing and refinements were made to achieve the ideal balance between performance and stability, particularly in rough sea conditions.
"The layout was carefully engineered to provide ample seating and comfort without affecting the vessel’s weight distribution. Small adjustments during the build phase ensured an optimal balance between seating capacity and overall stability."
Birgan and the SeaCat Ships team learned that engaging inspectors early in the process helped navigate compliance challenges more efficiently, reducing potential delays. Also, while simulations provided a strong starting point, in-water trials allowed for necessary refinements to further enhance performance.
Feedback from previous projects emphasised the need for both air-conditioned and open-air seating options, reinforcing the value of designing with passenger preferences in mind.
"Ultimately, overcoming these challenges has strengthened our expertise in high-speed ferry design, ensuring that Sea Express III is ready to excel in the US Caribbean," said Birgan.
Birgan believes the shipbuilding industry is adapting to a combination of regulatory changes and technological advancements. For one, the introduction of low-emission fuels (such as LNG, methanol, hydrogen) is impacting shipyard construction methods, requiring new fuel storage and handling systems.
"Smart shipbuilding practices, including robotic cutting and bending, AI-driven quality control, and digital twins, are improving efficiency and reducing build time. Also, material shortages and fluctuating aluminium prices are prompting shipbuilders to diversify suppliers and explore modular construction techniques to maintain production schedules."
Birgan commented that 2024 was "a strong year" for SeaCat Ships, with multiple successful vessel completions and new orders including a 23-metre whale watching catamaran for Sydney's coastal waters, a 19-metre inter-island ferry for West Africa, a 12-metre liveaboard vessel, and a 9.6-metre rescue/workboat for a marina operator in Thailand.
"Compared to previous years, there has been increased demand for efficient, high-performance vessels that balance speed, sustainability, and passenger comfort," he told Baird Maritime. "The industry is shifting towards more environment-friendly propulsion solutions, and SeaCat Ships is well-positioned to meet this demand.
"Given the ongoing need for innovative ferry and workboat solutions, we remain highly optimistic about the future."
Birgan remarked that the passenger ferry industry is seeing major advancements aimed at sustainability, efficiency, and passenger experience. First, battery-electric and hydrogen-powered ferries will become more common, particularly along short-haul routes.
"Air-conditioned cabins, better seating, and real-time journey tracking will enhance passenger experience," said Birgan. "More efficient hulls will meanwhile reduce fuel consumption and minimise environmental impact, particularly in sensitive marine ecosystems."
For a list of the 2024 "Best Of" award winners, please click here.
