To manage the many, often competing inputs on a project of this scale, BMComposites commissioned the Palma-based design house 3D Tech to bring together requirements from the service integration teams, composite engineers Gurit, and H2 Yacht Design, who drew the lines for the new Sky Lounge. Every feature and detail was captured in a single, comprehensive 3D CAD model, which stayed the primary reference through tooling, manufacture and installation.

The roof structure and mast were manufactured off-site in three main sections, then delivered to the yard for assembly and installation, with BMComposites project managers overseeing the process throughout. Building the components in composite from CNC-machined female tooling meant far less fairing than traditional aluminium construction would have required, a real advantage in a weight-sensitive area of the yacht.

Early 3D scanning of the deck also ensured an engineered fit for the large components, allowing the full roof to be installed in just two days with no hot works required on board.

Working closely with the captain, project management team, designers, engineers and subcontractors, BMComposites managed the process from initial briefing through to final commissioning. The Sky Lounge refit was described as the “jewel” of Coral Ocean’s €35m refit programme, and was recognised with a Judge’s Special Award at the Boat International World Superyacht Awards in 2023.

BMComposites coordinated inputs from the yacht’s original designers, FM Architettura d’Interni, together with Espen Oeino and Azure naval architects, engineering every unit for composite manufacture. 3D scans of the yacht’s mast were imported into the 3D CAD master model to ensure a precise interface with the new parts, while the mechanisms for the two electrically operated sunroofs were developed and specified in detail within the same model.

Large-scale female tooling was cut directly from the 3D CAD data to stay faithful to the original design intent. The hardtop was manufactured in two halves at BMComposites’ facility in Mallorca, then shipped to MB92 in Barcelona for assembly, with the furniture following shortly after for final assembly on site.

The jacuzzi, sized for eight people, featured glass panel frontage and underwater lighting, while the two large sunpads either side were manufactured at BMComposites’ Palma facility and shipped to Barcelona for installation during the yacht’s extensive refit at MB92.

Thanks to dedicated project management across every stage of manufacture and installation, BMComposites’ install team completed the hardtop on board in two days, with no hot works required and minimal disruption to other work on the upper deck.

The service bar and jacuzzi followed the same approach, bonded onto the deck in an operation that also lasted two days. With new dining, sunbed and bar areas and uninterrupted views, the sun deck was transformed into the yacht’s social hub.