A report by The Superyacht Agency predicts that refit activities for large superyachts over 60 m will increase by 50% by 2030. However, superyacht refitting requires many skills drawn from various disciplines: unlike new construction, it involves dealing with many unexpected challenges, making problem-solving skills and flexibility essential for success.
The process introduces constraints in several areas: design, engineering, manufacturing. From a design perspective, the challenge lies in achieving a delicate balance between the yacht’s original features and the new owner’s vision, which may be radically different.
Aesthetically, the changes must align harmoniously, respecting compatibility with the existing design.
On the technical side, the difficulties multiply. Modifications and upgrades must account for the yacht’s pre-existing conditions: its materials, structural elements, and aging equipment. This requires a creative and innovative approach, especially in engineering and manufacturing.
Moreover, the refit process must adhere to current regulatory standards, which have become increasingly stringent in terms of safety, environmental impact, and operational regulations. This adds another layer of complexity, as the refit must bring it up to the highest modern standards.
Where are the superyachts being refitted?
The United States leads in the number of refit yard visits for yachts over 30 m, driven by the high concentration of superyachts in South Florida. Italian yards rank second, benefiting from a leading role in new builds.
Spain and France follow closely, with significant refit hubs such as MB92 in Barcelona and Monaco Marine in France. Spain’s Palma de Mallorca is particularly noteworthy, with both STP and Astilleros de Mallorca operating there.
The Balearic Island has established itself as a premier destination for superyacht refits, thanks to its strategic location in the Mediterranean, excellent facilities, long-standing maritime tradition, and a well-established network of suppliers and service providers. The favorable climate allows for year-round work, a significant advantage over other regions. This makes Palma an attractive destination not just for routine maintenance but also for more extensive refit projects requiring longer timeframes.
BMComposites
BMComposites specializes in the design and manufacturing of carbon fiber composites. With a history dating back to 2005, the company has successfully handled numerous refits and repairs. Drawing on over 30 years of experience in the composite industry, key team members bring extensive expertise in the technical properties of composite materials, ensuring their optimal application in various projects.
The team has worked on a diverse range of superyacht components, including bowsprits, composite vent grills, deck furniture, hardtop biminis, helm consoles, shade systems, water ballast systems, aft deck reconstructions, tender bay modifications, deck hatches, ladders, and fenders.
Luke Hendy, Commercial Director, explains: “We draw on our experience and design ability to ensure that new additions made during a refit, whether large structural items or smaller components, feel akin to the yacht’s original design and are in keeping with the intended aesthetic.”
This experience and design ability are two of the main reasons why BMComposites’ expertise has been trusted by prestigious superyachts over the past two decades, from major superyacht modifications to the most challenging and complex upgrades for sailing yachts competing on their respective race circuits. Standout refit projects include the sailing yacht M5, the Wally Cento, the 73m superyacht Coral Ocean, and the 63m explorer yacht Polar Star.
Before diving into some of these notable projects, let’s take a broader view: what drives captains and yacht owners to refit a yacht? What challenges arise, and what capabilities must a company have to successfully manage a refit?
The goals and constraints of refits
Several factors can motivate a yacht owner to consider a refit.
In the last few years, the superyacht market had a great boom and the scarcity of attractive, readily available used yachts may lead some owners to purchase a less-than-ideal used yacht and undertake an extensive refit to tailor it to their needs.
Additionally, with over 150 new builds launched each year, the superyacht fleet continues to grow and age, and many of these vessels will of course necessitate regular maintenance and attention.
One of the most common goals of a refit is to modernize an aging superyacht. This modernization can be pushed by aiming for an enhanced comfort, or meet new market requirements or client’s demands, to make the yacht more appealing in the charter market or increase the vessel’s resale value.
Upgrading amenities—such as adding jacuzzis, gym areas, and improving outdoor spaces—can significantly enhance guest comfort. Other common enhancements might include extending the stern, creating new beach clubs, or modifying sundecks and flybridges.
Modernizing a superyacht often involves updating technology and systems to comply with current standards, including navigation, entertainment, domotics, and advanced HVAC systems. Incorporating energy-efficient propulsion systems and solutions is increasingly important as new sustainable regulations are introduced and are likely to become more stringent in the future.
George Loeff, head of research and development at Feadship, notes that it is becoming easier to convey to clients that a refit can be viewed as a sound investment. Modifications made during a refit can significantly improve efficiency and reduce fuel consumption, potentially enhancing the yacht’s resale value. Some upgrades, like installing LEDs throughout the vessel, may have a short return on investment, making them a worthwhile expenditure.
Sailing superyachts that compete in regattas also undergo refits to remain competitive in racing. BMComposites has worked on many projects for this purpose, ranging from modern Wally Cento yachts to iconic J-class yachts.
Key competencies for a successful refit
Every refit comes with various constraints. Among the many challenges that can arise, Luke Hendy points out that “time constraints are a huge one – you often start a refit and time constraints are such that you’re coming up with solutions at the same time as they’re being implemented. You really have to be able to think on your feet and tackle the requirements of your client, whether that be captain, crew, or relayed owner requests, and that too is a challenge – sometimes dealing with secondhand information rather than having a direct line of comms. Superyachts are the highest of the high end, but so often we’re expected to create something completely new, custom and one-off, usually without time for testing with prototypes etc – you just have to trust the idea and your ability to deliver. And it has to be perfect, with no budget impact and no delays. The greatest challenge in that case, perhaps, is client expectation and managing those.”
Budget management is also crucial, as refits often exceed initial budget estimates due to unforeseen issues. It is essential to maintain financial control and transparency throughout the process. Logistics and project management also play significant roles in the success of a refit. Coordinating between various contractors and suppliers can be complex, and managing a diverse workforce, which may include subcontractors from different regions, adds another layer of difficulty.
Handy further stressed the importance of the coordination and management of the all parties involves:
“There are times when we may have 40 different projects underway simultaneously, and the high-end execution of these projects speaks volumes about our capabilities. Managing all of this requires a particular talent! Every client is equally important, although each project has varying levels of complexity. When we are involved in large refit projects, many decisions may have already been made regarding parts, equipment suppliers, or even parts that have been ordered. This can lead to a greater level of customisation being required. Engaging BMComposites from the outset of complex projects could save tens of thousands.”
For new builds, skilled workers, experience, and well-equipped facilities are fundamental. A spokesperson for BMComposites highlighted that in refits, these factors can be even more crucial.
“In the refit business, foresight is difficult. You rarely get a long-term view of what’s coming, which makes it challenging to maintain a large, highly skilled team. There’s a significant skills shortage in boatbuilding, especially in the specialized skills required for refits, where you’re not working on a production line. At BMComposites, we depend on our experienced team, whose expertise is vital to the success of our business.”
In addition to these core skills, a strong network of partners and suppliers is essential for quickly addressing specific needs as they arise.
Lastly, leveraging modern technologies that weren’t available during the original construction can significantly enhance and expedite the refit process. For instance, 3D scanners allow for precise measurements in tight spaces, help assess hull and deck structures for extensions or modifications, and expedite the recreation of drawings for older vessels when original plans are unavailable.
Superyacht Coral Ocean
BMComposites played a pivotal role in the comprehensive rejuvenation of the iconic 30-year-old superyacht Coral Ocean. This extensive refit involved the removal of the previous satellite dome array from the upper deck, making way for the innovative new Sky Lounge. This fully enclosed entertainment area features a cinema, lounge, dining, and party spaces, marking a significant transformation of the yacht.
The project included the engineering, construction, and installation of a new composite roof structure for the upper deck of the 73m Lurssen yacht, previously known as Coral Island. This new 140sqm roof structure replaced the outdated technical area, creating an entirely new enclosed space ideal for entertaining, featuring two large electrically-operated sliding sunroofs, along with HVAC and AV systems. Additionally, a new 3.8m high navigation equipment mast was manufactured and installed atop the roof structure.
To ensure the successful integration of various inputs from designers and engineers, BMComposites collaborated with Palma-based design house 3D Tech to create a detailed 3D CAD model. This model served as a comprehensive reference throughout the project, guiding everything from tooling to final installation. The large roof structure and mast were manufactured off-site and delivered in three main parts, facilitating an efficient assembly process at the yard. Thanks to the precision of composite manufacturing and 3D scanning, the entire installation was completed in just two days, significantly reducing time spent on board.
The collaboration between BMComposites and the yacht’s captain, project management team, designers, and engineers ensured a seamless process from start to finish. The Sky Lounge was celebrated as the ‘jewel’ of the €35 million refit, showcasing the expertise and dedication of everyone involved, ultimately leading to the yacht’s recognition at the prestigious Boat International Superyacht Awards in 2023.
Explorer Yacht Polar Star
In 2015, BMComposites was tasked with engineering, building, and installing a 60sq.m carbon fiber hardtop bimini for the upper deck of the 63m Lurssen explorer yacht, Polar Star. Due to the yacht’s height—17m above the waterline—the use of lightweight carbon fiber was essential to maintain vessel stability, making aluminum construction impractical. The new hardtop featured two electrically-operated sliding sunroofs, providing the perfect blend of functionality and style.
The Palma-based company worked closely with multiple stakeholders, including designers from FM Architettura d’Interni, Espen Oeino, and Azure naval architects. Utilizing advanced 3D scanning technology, the team created a comprehensive 3D CAD master model that guaranteed a seamless interface with the yacht’s existing structures. Large-scale female tooling was produced directly from this model to preserve the designer’s original vision. The hardtop was manufactured in two halves and then transported to MB92 in Barcelona for final assembly.
The final installation of the hardtop was accomplished within just two days, with minimal impact on other ongoing works on the upper deck. The rapid installation process was similarly applied to the service bar and Jacuzzi, thanks to thorough pre-development work on all components. This efficiency allowed the installation team to focus on delivering a high-quality outcome without disrupting the yacht’s operations.
Wally Cento Galateia
BMComposites undertook a significant challenge to convert the concept design of the ballast system for the Wally Cento Galateia into a fully functional system comprising four tank volumes with automated pickup, transfer, and discharge capabilities.
The result was a finely tuned ballast system that significantly improved the performance of Galateia on the regatta fields.
The setup of the ballast system demanded meticulous attention to detail, particularly for the scoop intake mechanism, which was designed to fill tank volumes via a controlled master pump. This system allowed for the rapid transfer of several tons of water between tanks, a process that needed to be executed within six seconds to maintain optimal vessel trim. The physical forces involved in this operation presented significant risks to the integrity of the yacht’s structures, making precision in both design and installation crucial.
Luke Hendy explained: “We worked closely with the boat’s team to fully understand the operational requirements and develop a practical solution. There were many steps in the process—we consulted the original naval architect and a composite engineering company, prepared technical drawings, and more. Once work began, every item removed had to be weighed, as did every item being reinstalled.
Collaborating with industry experts such as Pure, Judel/Vrolijk, and Innovative Structural Design, BMComposites finalized the design layout to ensure it seamlessly integrated into the general arrangement.
Then, utilizing advanced manufacturing techniques, the team constructed ultra-lightweight CFRP parts in their state-of-the-art facility, employing 3D scanning, 3D printing, and CAD CAM CNC technology to enhance precision.
Mike Atkinson, Captain of Galateia, provided positive feedback, highlighting the team’s work:
“BMComposites has been delivering composite solutions for Galateia over the past two years, completing major projects such as the foredeck hatch, water ballast, internal structural modifications, and many smaller tasks. Galateia is heavily involved in the Maxi race circuit, where any composite solution must be highly weight-sensitive and completed within very tight timeframes. We needed a composite company with the capacity and infrastructure to handle complex modifications quickly and effectively. I also personally value good, professional communication with contractors, and BMComposites excels in all these areas.”
In addition to Galateia, a ballast system upgrade was also completed for the Wally 93 Bullitt.
Since Bullitt is smaller than Galateia, the VPP (Velocity Performance Predictions) for each boat differs, as do the methods to achieve them. While the scope of work was similar, it was not a simple copy-and-paste job.
Notably, S/Y Bullitt demonstrated the effectiveness of this upgrade by securing first place in IRC Class 1 at the 2023 Middle Sea Race, highlighting the success of this improvement.
Sailing Superyacht M5
Sailing Superyacht M5, formerly known as Mirabella V, is one of the largest composite sailing yachts ever built, boasting an impressive 75m length and a towering 89m mast, which was also constructed from composite materials. After years of dedicated service, BMComposites was enlisted to perform a comprehensive overhaul of the spreader foundations within the mast during an extensive refit of the vessel in 2019. This critical maintenance ensured that the yacht remained seaworthy and maintained its performance standards. In addition to this essential work, BMComposites collaborated with designer Adriana Monk to engineer, manufacture, and install three large carbon fiber hardtop biminis, which significantly enhanced the functionality of the flybridge.
The project involved taking the initial concept designs for the new biminis through various phases, including engineering, tooling, and manufacturing. Utilizing technologies such as 3D scanning and CAD modeling, BMComposites was able to produce the hardtops offsite, ensuring a seamless fit with the existing yacht structures upon installation. This approach not only streamlined the installation process but also allowed for meticulous attention to detail during each phase of production.
When the components were transported to the yard in Italy for final assembly, the efficiency of the pre-fabrication process became evident. The quick installation of the biminis ensured minimal disruption to ongoing operations, showcasing the advantages of advanced manufacturing techniques. This rapid deployment allowed the team to focus on achieving a high-quality finish while maintaining the yacht’s operational readiness.
