Naval Masts - The Integration Game - Global Defence Technology - Issue 141 - June 2023

5/23/24, 5:14 PM Naval masts: the integration game - Global Defence Technology | Issue 141 | June 2023
Feature
Naval masts: the integration game

A visible but lesser understood element to the silhouette of
a naval vessels is that of its mast, which contains all types
of sensors required for modern operations. Gordon Arthur The Saab Lightwe
reports. pictured here, will
Pohjanmaa-class m
construction for th
Saab
O
ne function of ship masts has stayed the same over the centuries, even if they are no longe
sails aloft. The principle of a sailor ensconced in a crow’s nest to give him the farthest view
valid, though of course this role has been taken over by advanced sensors. Yet the theory holds t
the sensors are, the more effective is their range.
A ship’s mast is always a compromise. Sensors need to be high to maximise range and performan
do not want them too high as this affects a vessel’s stability and radar signature. Furthermore, m
antennas must not interfere with each other, nor be unduly affected by all the ship’s steel. Mast d
represents the art of obtaining the best compromise.
Integrated masts
Over the years, naval architects have utilised various mast types, but the latest fashion is integra
being aesthetically pleasing, they reduce clutter by eliminating dozens of separate antennas, and
naval fare of radars, communications, navigation, identification friend or foe (IFF), fire control an
systems.
Sensors in integrated masts offer higher operational availability since sensitive components are
maritime environments, and maintenance can be carried out at sea. Other significant advantages
deck space, reduced topside weight for better ship stability, and greater flexibility/upgradability
https://defence.nridigital.com/global_defence_technology_jun23/ships_masts_integration_game 1/11
Although a covered mast might weigh more than a lattice mast, for example, it produces a smalle
suffers less vibration and can carry heavier loads. Myriad protrusions and antennas are a delight
an enclosed mast’s flat surfaces reduce reflective echoes.
Naturally, masts must be structurally integrated to endure static and dynamic loads as a ship mo
seas. Naval designers must also consider the position, for it impacts stability, air resistance and t
electromagnetic environment, plus mast sensors can be affected by heat plumes from funnels. Y
able to “see” through a mast’s panel structure. For example, the bottom half of the Advanced Enc
(AEM/S) of the LPD USS San Antonio is sheathed in a balsa core, while the top half is a sandwich
structural laminates.
The Republic of Singapore Navy operates eight 1,200-tonne Independence-class Littoral Mission Vessels that boast Saab’s
Integrated masts help deconflict electromagnetic and line-of-sight obstructions. Placed high ins
sensors and antennas with clear fields of view and reduced electromagnetic friction operate mor
omnidirectional and directional antennas simultaneously transmitting and receiving in different
place demands, but the aim is to achieve minimal performance degradation of each sensor and a
As an example, Thales Nederland created its Integrated Mast (I-Mast) family with four deck level
and lower antenna decks, and equipment deck – while a shielded duct routes cables and cooling
centre of the airtight mast. I-Masts are fitted to Royal Netherlands Navy Holland-class OPVs, for
Naval Group in France also offers integrated masts like the Panoramic Sensors and Intelligence M
to French Navy FDI frigates and Gowind 2500 corvettes, the PSIM can vary from 80 to 150 tonne
height. It can have anywhere from three to seven levels of operational and technical rooms, acco
fixed or rotating antenna.
A spokesperson from Naval Group explained: “The PSIM provides the ship with 360° operational
and communications. It is designed to meet the widest range of customer requirements in terms
consoles and electronic equipment. Because it is designed for a stand-alone operation ashore, eq
functional chains can be tested early before installation on board the ship, more than a year befo
identify any technical difficulties, characterise them and resolve them before going at sea.”
This is JS Kumano, the second Mogami-class frigate of the Japan Maritime Self-Defense Force. Evident is the UNICORN mas
different antenna types. Credit: Gordon Arthur
To gain true benefits from advance construction of the PSIM, Naval Group noted that “the PSIM
and therefore physical and functional integration studies have to be carried out during the early
programme. The equipment (radar, communications, etc) and Naval Group combat system softw
be available as soon as possible in order to secure the ship’s overall schedule.”
Furthermore, parallel construction means integrated masts can be powered up and fully tested s
construction. Once the vessel is assembled, its mast can be simply attached as a monolithic plug
only limited tests required thereafter to ensure successful integration. This construction indepe
shipbuilding cost and time savings. Further money is saved because sensors last longer and are e
their protected environment.
Japan’s developments
One of the newest masts available today comes from Japan. The UNIted COmplex Radio aNtenna
integrated mast is used on Japanese 3,900-tonne Mogami-class frigates being built by Mitsubish
Visually akin to a horn, the antenna-filled UNICORN sits above a plinth containing the OPY-2 act
scanned array radar.
Japan’s Acquisition, Technology and Logistics Agency (ATLA) picturesquely explained: “It’s an unp
with brand new stealth capabilities that are extremely advanced. Compared to a conventional an
radar cross-section is greatly reduced, like shrinking a kimono down to the size of a sensu foldin
In descending height, eight antennas are carefully arranged to avoid interference inside the UNI
reinforced plastic radome: radar-waveband omnidirectional detection antenna; communication-
search antenna; Wi-Fi-band antenna; Link 16 antenna; UHF-band transmit/receive antennas; IFF
and UHF/VHF-band transmit/receive antenna. In the UNICORN’s base is a tactical air navigation
Interestingly, ATLA moved the circular TACAN antenna to the very bottom, enabling the electron
(ESM) antenna to go at the top, for detecting incoming missiles, for instance.
Compared to previous masts on Japanese warships, the UNICORN’s height has reduced from 9m
removed by crane when the ship is berthed – a process taking several hours – and plug-in conne
cabling to the UNICORN’s baseplate. A lightning protection strip installed on the radome’s surfac
current surges.
Although the Type 052D destroyer is one of the most modern warships of China’s PLA Navy, the mast here on Yinchuan bea
crying out for radar detection. Credit: Gordon Arthur
Japan has offered to export the UNICORN to India, but the Indian Navy is exploring indigenous in
installation on future destroyers. India will execute this project in two phases, the first integratin
communications intelligence, VHF/UHF and data link antennas in a single mast. Phase two will in
Swedish innovations
Suppliers can customise the size and configuration of integrated masts, but one offering suitable
is the Saab Lightweight Integrated Mast (SLIM). The SLIM is used on Singaporean Littoral Missio
Navy Visby-class corvettes. The Finnish Navy will also employ it on Pohjanmaa-class corvettes. A
also been retrofitted onto existing surface ships like the Stockholm-class and Gävle-class corvett
Magnus Dannemyr, Saab Lightweight Integrated Mast’s product manager, told Global Defence Te
Kockums has been designing composite masts for decades. “SLIM is a lightweight design with ap
reduced weight or less when compared with a steel mast of the same design, while being non-co
material … The design also means it is a turnkey solution for simpler ship installation.”
Further discussing its merits, Dannemyr added: “SLIM is lightweight, which in turn gives reduce
increased ship stability, a higher mast to facilitate longer sensor range, and weight margin for m
and future growth. We can tailor it for enhanced performance based on customer and sensor ch
flexibility of its modular and scalable nature.”
Dannemyr acknowledged that a composite mast might initially be more expensive than a steel m
choice and design mean lower lifecycle costs and reduced maintenance than solutions made of s
Australia’s efforts
BAE Systems Australia has upgraded eight Anzac-class frigates for the Royal Australian Navy. A sp
Systems developed a specialist mast manufacturing capability at Henderson, Western Australia a
There, integrated mast modules are fabricated and outfitted prior to installation on the frigates.
The process includes blast and paint, insulation, piping, electrical cabling and equipment installa
the amount of work that needs to be conducted post-consolidation of the mast module on the sh
explained.
Anzac frigate masts use high-strength, marine-grade, aluminium alloys for mast module constru
shape of the mast, with tight dimensional tolerance requirements, has been largely driven by the
phased-array radar technology integrated by CEA Technologies, the spokesperson detailed. Afte
upgrade, the frigates carry CEAFAR2-L phased-array radars.
The aluminium enclosed masts of the Royal Australian Navy’s eight Anzac-class frigates were fabricated by BAE Systems Au
BAE Systems Australia is drawing on this experience to construct a proof-of-concept mast for th
class, with work already under way. Aluminium, because it is lightweight, frees up total gross we
elsewhere on the ship, thus contributing to future-proofing. “By removing weight from the struc
compromising strength or performance), the vessel has increased margins to add weight into wa
the spokesperson said. However, balance was described as key.
“By removing weight from the top of the ship, the vessel’s balance point moves lower, which mak
stable,” the spokesperson continued: “Construction and outfitting of the mast can be undertaken
independent of other work on the vessel and independent of the vessel being available. The work
readily accessible for trade staff, rather than having to conduct work in the ship environment, wh
pathway to execute such large work scopes.”
Integrated masts present their own challenges, though. “Interface control between the mast and
noted BAE Systems Australia. “The mechanical interface to the ship requires very tight tolerance
with aluminium, this is a challenge. The electrical interfaces need to be clearly thought through
which cable runs should come from the mast to the ship, and vice versa, to maximise efficiencies
"The support system interfaces for dry air, chilled water and HVAC also need careful consideratio
design phase to ensure interconnectivity has been considered. Forward planning for material an
availability to maximise the level of outfitting in the workshop environment can always be a chall
with long-lead-time equipment.”
Far from being an afterthought, or a simple framework upon which the real capabilities are moun
their ongoing evolution towards integration solutions is central at the very outset of design. The
incorporation of sensors into a viable structure appears to be a key element for current and futu
offering significant advantages over those services unable, or unwilling, to adapt to the pace of c

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5/23/24, 5:14 PM Naval masts: the integration game - Global Defence Technology | Issue 141 | June 2023

Naval masts: the integration game

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