Hull Crack & Impact Damage Repair

Cracks in a catamaran hull can compromise the entire vessel's structural integrity. Whether caused by grounding, collision, or fatigue stress, our engineers assess each case individually and apply the most effective repair methodology.

We use non-destructive testing methods to evaluate the full extent of hidden damage before beginning any repair work. This ensures that all compromised areas are identified and addressed, preventing recurring failures down the line.

• Full damage assessment using visual and tap-test inspection
• Removal of damaged laminate layers down to sound material
• Multi-layer fiberglass or carbon fiber rebuild to original specifications
• Gelcoat restoration and fairing for a seamless finish
• Post-repair load testing and quality verification

Osmosis Blister Treatment

Osmotic blistering is one of the most common issues affecting fiberglass catamarans. Left untreated, it leads to progressive delamination and structural weakening. Our treatment protocol addresses the root cause, not just the symptoms.

• Complete hull survey to map blister distribution and severity
• Gelcoat removal in affected areas to expose saturated laminate
• Controlled drying using professional moisture monitoring equipment
• Application of vinylester or epoxy barrier coat systems
• Multi-coat antifouling protection for long-term prevention

Delamination Repair

Delamination occurs when layers of a composite laminate separate, often due to water ingress, impact, or manufacturing defects. This is a serious structural concern that requires expert intervention.

We use resin injection techniques for minor delamination, and complete laminate reconstruction for severe cases. Every repair is engineered to restore or exceed the original strength of the composite structure.

Advanced Composite Techniques

Our team is proficient in the full spectrum of composite repair and fabrication methods used in modern catamaran construction.

Ideal for localized repairs and areas with complex geometry. We use precision hand lay-up with carefully controlled resin-to-fiber ratios to achieve consistent, high-quality results.

For larger structural repairs, vacuum infusion provides superior fiber-to-resin ratios and eliminates voids, resulting in lighter and stronger repairs that match factory-built quality.

Used for panel repairs and secondary bonding, vacuum bagging ensures optimal consolidation pressure across the entire repair area, producing dense, void-free laminates.

Materials We Use

We work exclusively with marine-grade, high-performance materials to ensure every repair meets the highest standards of strength and durability.

• BXE Fiberglass – Biaxial E-glass fabric for excellent strength-to-weight ratio in standard structural repairs
• BXC Carbon Fiber – Biaxial carbon fiber for high-stress areas requiring maximum stiffness and minimum weight
• Vinylester & Epoxy Resins – Superior water resistance and mechanical properties compared to polyester
• Structural Core Materials – PVC foam, balsa, and honeycomb cores for sandwich panel reconstruction

Porthole & Hatch Repairs

Leaking portholes and hatches are not just an inconvenience – they can lead to interior water damage and structural degradation. We replace seals, re-bed frames, and where necessary, install entirely new units to guarantee watertight integrity.

• Seal replacement and re-bedding with marine-grade sealant
• Frame reinforcement and structural repair of surrounding laminate
• Complete porthole or hatch replacement when required
• Leak testing and verification after every repair

Deck & Structural Reinforcement

Decks bear constant loads from equipment, rigging, and foot traffic. Core degradation, soft spots, and localized damage are common on aging catamarans. We reinforce and rebuild deck structures to handle the demands of ocean sailing.

Our approach includes core replacement with modern closed-cell foam, laminate reinforcement in high-load areas, and re-engineering of equipment mounting points for winches, davits, and solar panel arrays.