LOTS Shipping has completed the haul-out and docking of a 112-tonne aluminium twin-hull passenger catamaran for underwater inspection and maintenance, using an innovative engineering solution involving inflatable salvage balloons—an operation believed to be among the first of its kind in India for a vessel of this size and configuration.
The project involved docking a 46-year-old aluminium catamaran, whose ageing lightweight structure required meticulous load management to prevent deformation or structural damage. Unlike conventional steel vessels, the aluminium hull lacked certified strong points for direct hauling, while the use of traditional wire rope chokers was ruled out to avoid damaging the hull plating and structural extrusions.
The operation was further complicated by severe site constraints, including limited working space and bridge air-draft restrictions that prevented the use of conventional lifting and positioning methods.
To overcome these challenges, LOTS Shipping’s technical team developed a customised docking methodology using wide synthetic web slings around the transom, controlled multi-stage winching and inflatable salvage balloons. The approach ensured balanced load distribution between the vessel’s twin hulls throughout the haul-out process, allowing the catamaran to be safely docked without damage. The vessel is now undergoing underwater inspection and maintenance.
According to LOTS Shipping, this is among the very few documented instances in India where a large aluminium twin-hull passenger catamaran has been hauled ashore on inflatable salvage balloons for dry docking. The company noted that while similar techniques may have been employed elsewhere, the combination of the vessel’s size, age, aluminium construction and challenging site conditions makes the operation particularly significant.
The project also highlights LOTS Shipping’s long-standing expertise in alternative docking solutions. The company said it pioneered the use of inflatable docking balloons in India’s small shipyard sector nearly two decades ago, providing a practical alternative where conventional dry-docking infrastructure is unavailable.
Over the years, LOTS Shipping has successfully docked, undocked or launched more than 50 vessels using inflatable balloon technology. The largest vessel handled through this methodology has been a 700-tonne lightship coaster, demonstrating the viability of engineered balloon-assisted docking for a wide range of vessel types.
The company emphasised that inflatable docking balloons offer an economical and technically proven solution for small and medium-sized shipyards, where the cost of establishing graving docks, synchrolifts, boat lifts, straddle carriers or rail slipways is often prohibitive.
LOTS Shipping also called for greater institutional support for India’s maritime MSMEs, stating that strengthening technically capable small and medium enterprises will be essential for building long-term industrial capability and achieving the country’s maritime ambitions. The company noted that many of the world’s leading maritime industries—including those in Denmark, Greece and the Netherlands—have evolved from strong ecosystems of small, specialised maritime enterprises.
The successful docking of the aluminium catamaran, the company said, demonstrates how engineering innovation and careful planning can overcome complex operational constraints while providing cost-effective solutions for the ship repair sector.
