Case Studies – Coral Ocean
Brief
BMComposites was commissioned to engineer, build and install a new composite roof structure for the upper deck of the classic, Bannenburg & Rowell-designed motor yacht Coral Ocean (formerly Coral Island) – a 73m, 30-year-old, Lurssen. The new 140sqm roof structure would replace a sat dome technical area on the upper deck, so creating an entirely new enclosed space for entertaining, dining and parties. The roof structure would also include two large electrically-operated sliding sun roofs, plus HVAC and AV systems.
Also included in the upgrade was the manufacture and installation of a new 3.8m high navigation equipment mast atop the new roof structure.
Approach
BMComposites commissioned the Palma-based design house 3D Tech, to integrate the many and often conflicting inputs from the service integration companies, the composite engineers, Gurit and H2 Design Yacht Design who drew the lines for the new Sky Lounge. All features and details were captured in a comprehensive 3D CAD model, which became the primary reference throughout the project lifecycle from tooling, component manufacture and final installation.
The large roof structure and mast was manufactured off-site and delivered in three main parts before being assembled in the yard and installed on board, with BMComposites project managers overseeing the entire process. Due to the use of composite manufacture using CNC-machined female tooling, the parts required very little fairing when compared to traditional aluminium construction – so making significant gains in an extremely weight-sensitive area. The use of 3D scanning at the outset ensured a perfect fit of the huge components and allowed for full installation of the roof in two days with no requirement for hot works on board.
The Result
BMC worked closely with the Captain, project management team, designers, engineers and sub-contractors to manage the entire process from initial briefing to installation and final commissioning. The Sky Lounge refit was described as the ‘jewel’ of the €35m refit, which was credited with a prestigious Judge’s Special Award at the Boat International Superyacht Awards in 2023.