Efficient lightweight construction, enormous corrosion resistance and the possibility of aesthetic shaping are some of the outstanding features of fiber-reinforced plastics that have been used in the projects for cladding, superstructures and structures. All assemblies were looked after in-house from design to assembly.

The companies: North German shipyards

The shipyards in Hamburg, Bremen and Schleswig-Holstein have been producing the largest yachts in the world for many years and are therefore market leaders in the mega and superyacht segment, not least because of their good network of suppliers.

The challenge: form, strength and function

Whether a desired weight reduction or a design that can be difficult to achieve with steel or the maritime climate, which affects steel structures. Fiber-reinforced plastic offers solutions to these problems.

The solution: FRP

Fiber reinforced plastic (FRP) offers less weight but greater strength and rigidity than the traditional use of metals. Building with FRP also allows a high degree of artistic freedom in the design, as almost anything is possible when building with FRP. The non-corrosive material reduces subsequent maintenance compared to metals, making the assemblies ideal for the maritime environment.

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Based on the designers’ 3D models, the pool landscapes were designed and manufactured from glass fiber reinforced plastic. Measurements taken on board. Visible components embedded flush into the surfaces. Integrated buffet and slide-in furniture. Handrails, glass panes, hatches were purchased and adjusted in advance. The pool landscapes were delivered to the shipyard in several pieces, connected to each other and attached to the ship structure by gluing. The interface to the shipyard was the empty deck.

The company: Northern German shipyards

The shipyards in northern Germany have been producing the largest yachts in the world for many years, making them the global market leader in the mega and superyacht segment. In the 2021 order backlog for civil shipbuilding, megayachts ranked right after cruise ships and are therefore a permanent fixture in the maritime economy.

The challenge: equipment

The designers of the yachts place high demands on the quality and appearance of all components. Everything has to be perfect and reflect the design concepts. The equipment must be integrated in the best possible way. These interfaces must be maintained. Here we are relieving capacity in the construction departments of the shipyards.

The solution: interface support

Depending on the scope of services ordered, we have taken over interface support from the shipyards and take care of the design, procurement and assembly of the high-quality equipment, thereby keeping the “big picture” in mind. There is no need for technical coordinations between various parties. If the shipyard and the owner representatives approve our designs, we will get started.

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The production and assembly of Jacuzzis and their technology are among the “top class” of modern yacht structures. Design and scope of services vary from project to project. From the unequipped basic pool to the fully equipped complete jacuzzi with an adjoining lounge area and equipment such as glass panes, handrails, stone tops, steel racks and complex water technology, all services are fulfilled. All of this with an eye for detail.

The company: Northern German shipyards

The shipyards in Hamburg, Bremen and Schleswig-Holstein have been producing the largest yachts in the world for many years and are therefore market leaders in the mega and superyacht segment, not least because of their good network of suppliers.

The challenge: environmental conditions

Strong sunlight. Operating temperatures around 40 °C. The chemistry of the water treatment systems and the input from users result in heavy wear and tear on all materials and surfaces.

The solution: material selection

A suitable selection of materials, through a hydrolysis and UV-resistant gelcoat and a support laminate made of certified resins in combination with a suitable structure of reinforcement layers. If desired, with a sandwich, which not only provides high rigidity but also increases insulation. High-gloss or prepared for tiling. Stainless steel components. Tempered glasses. Sealants and adhesives that withstand the maritime climate.

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The slim satcom mast, whose sleek sweep and spoiler signal the dynamics of the mega-yacht, shows the high potential of GRP as a material in yacht construction. Strength and lightweight construction characteristics, shiny, smooth surfaces without markings and clean lines were only achieved through high-quality resins, optimal laminate structure, sophisticated tooling and high manufacturing quality at Hahlbrock.

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The similar but not identical bulwarks were carried out as a Turn Key including engineering, FE-calculation of the structures and their connection, class drawings, manufacturing, equipping with niche and liferaft integrations, as well as their assembly at the shipyard by our employees. The interface was the decks on which the GRP superstructures were placed and glued. The weight was reduced immensely compared to steel and the bulwarks could be assembled after the “hot works” in the equipment phases. By producing large-format sections, assembly time could be reduced.

The company: Nobiskrug GmbH

Nobiskrug GmbH is a shipyard based in Rendsburg on the Kiel Canal. The shipyard, which currently has around 400 employees, is particularly known for building superyachts.

The challenge: complex designs

Complex designs are difficult to produce from steel, especially when high contour precision is required. This repeatedly leads to excessive filler application on the steel structures, which in extreme cases leads to cracks.

The solution: large-format lightweight fortification made of GFRP

The constructions made of glass fiber reinforced plastics, made from milled negative molds in maximum transport dimensions with a “ready to use” surface for a minimum filler application of 3 mm. Significant weight savings compared to the steel filler solution. Low maintenance thanks to the non-corrosive material.

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