RoRoSafe
RoRoSAFE
INITIALIZING THERMAL GRID ARRAY·00%
Maritime Thermal Intelligence

Prevent EV Fires Before They Start.

Incident Register
VesselEst. Loss (USD)Year
Sincerity Ace~$120M – $200M2019
Felicity Ace~$438M – $500M2022
Fremantle Highway~$300M – $600M2023
Morning Midas~$150M – $350M2025
Sincerity Ace~$120M – $200M2019
Felicity Ace~$438M – $500M2022
Fremantle Highway~$300M – $600M2023
Morning Midas~$150M – $350M2025
14+ decks
up to 6,000+ vehicles
< 30 min
Pre-ignition lead · target
IP68
Marine-grade grid
Engineered for
RoRo Fleets
4 total lossesPCTC casualties · 2019–2025
$1B+Reported insured loss

Incident losses are public reported estimates (Allianz Commercial Safety & Shipping Review; EMSA; Lloyd's List / TradeWinds) and vary by source. Detection-lead and enclosure figures are RoRoSafe engineering targets, not field-measured results.

The silent threat at sea

An EV battery failure at sea is not a warning. It's a verdict.

Thermal runaway in a single EV can ignite hundreds more — yet conventional fire systems only trigger after combustion. RoRoSafe detects the chemistry of failure, not its aftermath.

T − hours
STAGE 01

Gas release

Lithium-ion cells begin venting electrolyte vapor and volatile organic compounds long before visible signs appear.

T − 30 min
STAGE 02

Temperature rise

Cell impedance drops, neighboring cells heat up and a localized thermal gradient forms inside the battery pack.

T = 0
STAGE 03

Smoke & ignition

Runaway propagates to adjacent vehicles. Conventional fire systems react only after ignition — often too late.

Catastrophic ship loss

Total fleet and vessel write-off in minutes.

Toxic HF gas release

Crew exposure and long evacuation windows.

Fleet-wide liability

Cascading claims across cargo and hull insurers.

Insurance impact

Rising premiums and tightening EV cargo clauses.

Product architecture

One integrated grid. Three layers of protection.

From passive sensing tiles bolted under the deck, to a deterministic industrial bus, to a fleet-wide AI dashboard — RoRoSafe is engineered as one seamless maritime thermal intelligence platform.

Edge HardwareMOD-01

Sensor Grid Tile

  • IR thermal sensing
  • Multi-gas detection (H₂, VOC)
  • Vehicle presence sensing
  • Marine-grade IP68 enclosure
Industrial BusMOD-02

Segment Master

  • EtherCAT industrial fieldbus
  • Local fail-safe storage
  • Dual-path redundancy
  • Sub-second anomaly latency
AI PlatformMOD-03

AI Monitoring Dashboard

  • Fleet-wide thermal heatmap
  • Predictive anomaly detection
  • Tiered alert escalation
  • Audit-grade event logs
Sensor Tiles
×4,400
Segment Masters
EtherCAT
Vessel Gateway
Edge AI
Fleet Cloud
Compliance
Why RoRoSafe

Engineered for the worst day at sea.

Four pillars that make RoRoSafe the first category-defining thermal intelligence platform for vehicle carriers.

Detect before ignition

Catch off-gassing and thermal drift hours before any visible smoke — while intervention is still possible.

Hours of lead time

Non-invasive retrofit

Installs under-deck without touching vehicles, batteries, or OEM warranties. No drilling, no downtime.

Zero vehicle contact

Marine-grade reliability

IP68 hardware rated for salt fog, vibration, and deck temperatures.

IP68 · marine-grade

Audit-grade event logs

Tamper-evident event logs, audit trails and export-ready reports designed to align with IMO and classification guidance.

Tamper-evident
§ 04 / TIMELINE
The detection lead

30 minutes of warning vs. 3 minutes of crisis.

Eight events from 30 minutes before ignition to 6 minutes after. RoRoSafe owns the proactive window; legacy systems only act once the fire is established.

Illustrative reference scenario · lead times are RoRoSafe targets (off-gas-before-runaway sequence; DNV, NTSB, Li-ion venting literature), not field-measured.

Proactive zone · RoRoSafe
  • T-30m
    Anomaly · gas precursor
    VOC spike +312% above baseline
  • T-22m
    Cell venting confirmed
    VOC drift cross-correlated with thermal Δ
  • T-15m
    Pre-ignition gases rising
    Tier-2 alert · captain notified
  • T-8m
    Thermal runaway threshold
    ΔT +14°C · 90 s decision window
  • T-2m
    Last-resort intervention
    Halon zone primed · evac ordered
T+00 · Ignition
IGNITION
Cell rupture · open flame
Reactive zone · Legacy
  • T+03m
    CCTV detects smoke
    Already too late · fire established
  • T+06m
    Sprinklers activate
    Cannot suppress Li-ion thermal runaway
RoRoSafe
detects pre-ignition
Multi-modal · non-invasive under-vehicle thermal sensor · pre-ignition lead (target)
CCTV / smoke
reactive · 3 min lag
Vision-based detection · only fires after visible smoke
Sprinklers
suppression
Designed for hydrocarbon · cannot suppress Li-ion runaway
§ 05 / ARCHITECTURE
EtherCAT ring · 110 nodes / segment

Each segment is a self-healing ring. A single broken node cannot blind the deck. Hover any sensor for live telemetry.

  • Step · 01
    Per-vehicle bay
    Sensor cells
    IR thermal + multi-gas detection. One non-invasive cell per parked vehicle, IP66 marine-grade.
  • Step · 02
    EtherCAT ring · 110 nodes
    Segment master
    Hardware fieldbus controller. Sub-millisecond polling, self-healing redundant ring topology, < 1 ms failover (bench).
  • Step · 03
    Bridge console
    Captain Deck AI
    Cross-cell coherence and anomaly fusion. End-to-end measurement-to-alert in under 4 seconds (bench target).
Nodes / segment
110
Topology
Ring + redundant
Failover
< 1 ms
Power / node
0.25 W
Update rate
50 Hz
MTBF
> 200 000 h
Bench figures · current engineering revision. Restated against type-approval test reports as each programme completes.
How it compares

Not a replacement. An early-detection layer.

Fixed suppression and ceiling detection are mandated, mature, and necessary. None of them was built to see a lithium-ion battery off-gassing under a car before there is smoke. That gap is what RoRoSafe fills — alongside the systems below, not instead of them.

CO₂ Flooding
Fixed gas
  • Detects pre-ignition off-gas
  • Per-vehicle resolution
  • Covers the under-vehicle space
  • Audit-grade forensic log
  • Non-invasive · no drydock
  • Suppresses an active fire
  • SOLAS-mandated today
Best role · Last-resort suppression
Water Mist
HI-FOG class
  • Detects pre-ignition off-gas
  • Per-vehicle resolution
  • Covers the under-vehicle space
  • Audit-grade forensic log
  • Non-invasive · no drydock
  • Suppresses an active fire
  • SOLAS-mandated today
Best role · Fixed suppression
Smoke + Heat
Ceiling FSS Ch.9
  • Detects pre-ignition off-gas
  • Per-vehicle resolution
  • Covers the under-vehicle space
  • Audit-grade forensic log
  • Non-invasive · no drydock
  • Suppresses an active fire
  • SOLAS-mandated today
Best role · Mandated detection
Thermal CCTV
Video analytics
  • Detects pre-ignition off-gas
  • Per-vehicle resolution
  • Covers the under-vehicle space
  • Audit-grade forensic log
  • Non-invasive · no drydock
  • Suppresses an active fire
  • SOLAS-mandated today
Best role · Visual confirmation
RoRoSafe
Per-vehicle grid
  • Detects pre-ignition off-gas
  • Per-vehicle resolution
  • Covers the under-vehicle space
  • Audit-grade forensic log
  • Non-invasive · no drydock
  • Suppresses an active fire
  • SOLAS-mandated today
Best role · Early-detection layer
Honest trade-offs
Capital cost

CO₂ flooding and ceiling smoke + heat detection are already fitted and class-mandated — their marginal cost is near zero. A water-mist retrofit (e.g. Marioff HI-FOG) is a major capital and drydock commitment. RoRoSafe is new capital expenditure; its case rests on avoided-loss economics, not on being free.

Maturity & approval

Fixed gas, water mist, and ceiling detection have decades of service history and classification-society type approval. RoRoSafe is early: type-approval engagement is in progress and we hold no class approval yet. Bench figures on this site are labelled as bench.

Detection, not suppression

RoRoSafe does not extinguish a fire. It is the layer that sees a battery off-gassing before there is smoke, and buys decision time before fixed suppression must activate. It complements CO₂ and water mist — it does not replace them.

FAQ

Questions about
the system.

What RoRoSafe is, how it deploys, and where it sits alongside your existing fire-safety systems.

RoRoSafe is a non-invasive thermal and gas detection grid for vehicle carriers. A sensor cell sits beneath each parked vehicle on an enclosed deck, observing per-vehicle temperature and battery-vent gases continuously, and a fleet-side platform turns that telemetry into tiered bridge and shore alerts — closing the detection lag between an EV battery fault and crew intervention.

Conventional ceiling-mounted smoke and heat sensors only trigger once a fire has grown enough to reach them. RoRoSafe observes each vehicle directly with infrared thermal and electrochemical gas sensing, fusing both signals to flag a developing thermal event from vapour-phase off-gassing before visible smoke — in bench testing, 18–25 minutes ahead of ceiling smoke detection.

Yes. The system is non-invasive — no drilling of the deck, no modification to vehicles, and no hull changes. A single deck installs alongside the berth in roughly three working days, with no drydock required. The mounting method is the subject of a pending patent and is documented for pilot customers under NDA.

For every vehicle bay it tracks an infrared thermal field, electrochemical gas signatures associated with lithium-ion electrolyte venting (including hydrogen and characteristic VOCs), and vehicle presence. Telemetry is aggregated over a deterministic EtherCAT-class network and delivered to the bridge console with end-to-end measurement-to-bridge latency under four seconds.

No. RoRoSafe is the early-detection layer, not a suppression system. It is designed to sit alongside a vessel’s existing SOLAS fire-safety systems and buy crews time — surfacing a developing event early enough that the established response and suppression procedures can be used while the situation is still containable.

It is built for PCTC, ConRo, and RoPax tonnage carrying electric vehicles, and extends to port and terminal EV staging yards. The same per-vehicle grid pattern works on enclosed cargo decks and on landside storage, so operators, ports, and insurers can apply one detection approach across the EV supply chain.

A standard pilot covers one nominated deck on one vessel, deployed alongside the berth without drydock, with twelve months of bridge and shore-side dashboard access and a joint insurer/class-society review at the end. It stands alone commercially and is structured to extend to a full vessel, then a fleet, without architectural changes.

Not yet. RoRoSafe does not currently hold classification-society type approval or ISO/IEC 27001 certification, and we do not claim to. Type-approval engagement with IACS member societies begins as the engineering revision freezes for first deployment; once any programme awards approval, the certificate details are published on our Compliance page.

The architecture is modular. Each deck is split into failure-isolated segments served by redundant segment masters, so coverage grows from a single deck to a full vessel and then across a fleet with no architectural change. A fault in one segment never compromises vessel-wide monitoring, and the dashboard presents fleet-wide thermal posture in one view.

Pilot program open

Protect your fleet before the first spark.

Request a pilot deployment on a single deck. Our team works alongside your classification society and insurer from day one.

No vessel downtime
Removable, no hot work
NDAs welcome
Pilot packageLimited 2026
Deck-level deployment
End-to-end install, calibration and 12-month data access.
  • On-board sensor grid for one deck
  • Redundant segment masters
  • Fleet dashboard access
  • Joint insurer review report
  • Dedicated safety engineer