Recently, while preparing for a PCTC (Pure Car and Truck Carrier) condition survey, I found myself revisiting technical manuals, inspection guides, and vessel drawings that I had not looked at for years.
Interestingly, I had actually sailed on a PCTC during my cadet days.
At the time, however, I was focused on learning my daily duties, understanding machinery systems, and simply trying to survive life onboard.
Like many cadets, I was busy learning how things worked, but I did not fully understand why they were designed that way.
Now, while preparing for condition surveys, I find myself looking at the same vessel from a completely different perspective.
Details that once seemed ordinary suddenly appear much more important.
And perhaps that is one of the most interesting aspects of becoming a surveyor.
You begin to see the vessel as an integrated system rather than simply a workplace.
My First Impression of a PCTC
Most people who see a PCTC for the first time have a similar reaction.
“Why does it look like a giant floating building?”
Compared with bulk carriers, tankers, or LNG carriers, the shape of a PCTC is certainly unusual.
The vessel appears almost rectangular from the outside, with a large box-like superstructure extending above the main deck.
When I first boarded one, I remember thinking that it looked more like a multi-story parking garage than a ship.
Once inside, that impression became even stronger.
There were no cargo holds filled with iron ore.
No cargo tanks carrying oil.
No container stacks.
Instead, the entire vessel consisted of multiple vehicle decks connected by ramps.
It was essentially a floating parking structure capable of transporting thousands of vehicles across oceans.
What Exactly Is a PCTC?
PCTC stands for Pure Car and Truck Carrier.
As the name suggests, these vessels are specifically designed to transport:
- Passenger cars
- Trucks
- Buses
- Construction equipment
- Rolling cargo
Many of the vehicles produced by manufacturers such as:
- Hyundai
- Kia
- Toyota
- Volkswagen
- BMW
spend part of their journey aboard PCTCs before reaching dealerships around the world.
When people purchase a new vehicle, they rarely think about the logistics involved in moving it across continents.
Yet behind every vehicle shipment lies an incredibly specialized transportation system.
A Completely Different Inspection Philosophy
During my career, I have sailed on various vessel types, including LNG carriers and conventional merchant vessels.
Every ship has its own operational characteristics.
However, PCTCs are fundamentally different.
A bulk carrier transports commodities.
A tanker transports liquids.
An LNG carrier transports cryogenic cargo.
A PCTC transports thousands of individual vehicles.
This difference changes everything.
It changes cargo operations.
It changes safety considerations.
And it significantly changes what surveyors pay attention to during inspections.
The Stern Ramp: Much More Than a Door
When I was younger, I viewed the stern ramp as little more than a large loading door.
Now I realize how critical this structure actually is.
The stern ramp is the primary gateway through which cargo enters and leaves the vessel.
Without it, cargo operations effectively stop.
Modern stern ramps are sophisticated structures that incorporate:
- Hydraulic cylinders
- Wire systems
- Limit switches
- Locking arrangements
- Sealing systems
- Structural reinforcement
Thousands of vehicles may pass across this structure during a single port call.
As a result, even relatively minor defects can become operationally significant.
What Would a Surveyor Look For?
One of the biggest changes in my thinking has been learning to view equipment through a surveyor’s eyes.
Years ago, I probably would have asked a simple question:
“Does it open and close properly?”
Today, I ask very different questions.
For example:
- Are there visible cracks?
- Is there structural deformation?
- Is corrosion affecting load-bearing areas?
- Are hinge connections showing excessive wear?
- Is there evidence of hydraulic oil leakage?
Particular attention is often given to hydraulic cylinder rods.
Even small scratches can damage seals and eventually result in hydraulic leakage.
These seemingly minor details may indicate larger maintenance issues.
Internal Ramps: The Hidden Lifeline of Cargo Operations
The stern ramp is only part of the cargo handling system.
Inside the vessel, vehicles move between decks using internal ramps.
The best comparison is a multi-story parking garage.
These ramps allow vehicles to travel between cargo decks quickly and efficiently.
Because they experience continuous vehicle traffic throughout the vessel’s operational life, surveyors often examine:
- Structural deformation
- Fatigue cracking
- Corrosion
- Hydraulic arrangements (where applicable)
- Ramp locking mechanisms
Damage in these areas can directly affect cargo handling efficiency and safety.
Cargo Securing: More Important Than Many People Realize
One area that impressed me while studying PCTC operations was cargo securing.
At first glance, automobiles may seem like relatively harmless cargo.
In reality, thousands of vehicles represent a significant moving mass.
Unlike containers, vehicles are not inherently fixed to the vessel.
Every vehicle must be properly secured.
Typical securing arrangements include:
- Lashing chains
- Turnbuckles
- Wheel chocks
- D-rings
If securing arrangements fail during heavy weather, the consequences can be severe.
A single vehicle movement may trigger a chain reaction affecting multiple units.
For this reason, cargo securing equipment receives considerable attention during inspections.
Understanding Watertight and Splash-Tight Doors
While reviewing PCTC structures, I found myself revisiting a concept that often causes confusion.
Many people assume that all doors designed to keep water out serve the same purpose.
In reality, there is an important distinction.
Watertight Doors
Designed to prevent water ingress during flooding situations.
Splash-Tight Doors
Designed to prevent ingress from rain, spray, and sea splash.
Watertight doors typically feature significantly stronger sealing arrangements and structural construction because they must withstand hydrostatic pressure.
Understanding this distinction is important during inspections because each type serves a different safety function.
The Growing Challenge of Electric Vehicle Transportation
One of the most significant developments affecting modern PCTCs is the rapid growth of electric vehicle transportation.
Historically, vehicle carriers primarily transported gasoline and diesel vehicles.
Today, the number of electric vehicles continues to increase.
As a result, fire protection systems are receiving greater attention than ever before.
Surveyors and operators increasingly focus on:
- Drencher systems
- Smoke detection systems
- Fire dampers
- Ventilation shutdown arrangements
- Emergency response procedures
The industry continues to adapt as vehicle technology evolves.
What Preparing for Surveys Has Taught Me
When I first became interested in condition surveys, I viewed inspections rather simply.
I assumed the objective was to identify defects.
Find corrosion.
Find cracks.
Find problems.
The more I study vessel inspections, however, the more I realize that this view is incomplete.
The real objective is understanding the vessel.
A surveyor is not merely evaluating steel condition.
A surveyor is evaluating:
- How the vessel is operated
- How risks are managed
- How maintenance is performed
- Whether critical systems remain fit for service
Corrosion and defects are only part of the story.
The larger question is whether the vessel is being managed in a way that ensures continued safe operation.
Final Thoughts
Preparing for this PCTC condition survey reminded me how much perspective changes with experience.
As a cadet, I saw a floating parking garage.
Today, I see a highly specialized vessel designed to safely transport thousands of vehicles around the world.
The ship itself has not changed.
What changed is my understanding of it.
And perhaps that is one of the most rewarding aspects of studying ships and conducting inspections.
The more you learn, the more details you begin to notice.
And the more details you notice, the more fascinating these vessels become.