Ever wondered how to build a superyacht? How many stages are involved? And how long does it take before an owner can officially set sail? BOAT takes you through a superyacht's construction journey, from signing the contract to decommissioning...
Commissioning
The client (and future owner) signs a contract with a shipyard requesting that a superyacht be built. This can either be a custom, semi-custom or production build, with construction time varying between one to five years (depending on the project's complexity).
Note: This is an optional first step. Some yards, such as Heesen, will begin building 'on speculation' (on spec) to find a buyer before construction is complete. Production yards, such as Beneteau, will build several units on spec as the models are smaller and typically quicker to sell.
Keel-laying
Keel-laying is the formal recognition of the beginning of the construction process. This stage is marked by the placement of the central beam that makes up the foundation of a superyacht's hull, whether made from steel, composite, aluminium or wood.
As modern superyachts – particularly semi-custom or production models – are made by combining sections that have been built separately, the keel-laying can sometimes mean lowering the first module into the building dock. A largely symbolic event, the owner (or their representatives) will often be in attendance, alongside key team members from the shipyard, the brokerage firm involved in the commission and other shareholders.
Completing the hull
Superyachts are comprised of two major sections: the hull and the superstructure. The first major stage in construction is completing the hull, though how this is done varies depending on the yacht's materials.
Quick glossary
Hull: The lowermost portion of a yacht, partially submerged, providing buoyancy and supporting the entire vessel
Superstructure: Everything built above the hull, including all outdoor decks
Hull turning
This applies to metal superyachts (steel and aluminium), which are typically built upside down because of the hull's shape. The lower portion is curved and more complex, while the upper portion – the deck – is relatively flat and stable. As a result, working on a build upside-down is more intuitive and results in a quicker, less complicated building process. For example, the metal plates that comprise the hull are welded or riveted together with the help of gravity. Once the structure is complete, it must be turned the right way round to prepare for the next stage of construction.
Hull lamination
This applies to composite superyachts. Hull lamination is the process of building a yacht hull by layering materials like fibreglass and resin over a pre-built framework, typically made of lightweight materials like foam or wood.
Hull infusion
This is an alternative method of composite construction typically reserved for smaller builds. A hull mould is created, which is then vacuum-sealed and injected with resin, with the lack of air forcing the resin to fill the space left by a fibreglass framework. The largest single-shot hull infusion recorded is on Sunreef Yachts' 43M Eco.
Hull and superstructure joining
Once the hull is complete, it must be connected to the superstructure. At this point, the superyacht will start to take a familiar shape. This is typically done in the construction shed but can be moved outdoors or on the water if the yacht is particularly large (as is the case with the Feadship pictured above, a 100-metre build known as Project 824).
Metal superyachts will have the hull and superstructure welded together, while composite superyachts will have the two pieces joined through a combination of mechanical fasteners and adhesive bonding.
Outfitting
Outfitting is a broader stage than others on this list. It involves equipping the superyacht with everything it will need, from electrical and engineering works to interior furnishings and exterior paint and finishing. The superyacht will be transported to a specialised shed (or separate shipyard) to begin the process, which can take anywhere between six to 18 months.
The more extensive outfitting periods are reserved for incredibly complex builds, such as the 194.9-metre REV Ocean (also known as the world's largest superyacht).
Launch
Like a keel-laying, the launch of a superyacht is a highly ceremonial part of the construction process. In most cases, this will be the first time the build is transferred from land to water, marking the beginning of her cruising journey. Launches will have a similar set-up to a keel-laying, gathering the owners, builders and other shareholders to celebrate the milestone together. Traditions associated with the shipbuilding industry – including the official christening and breaking a bottle of champagne on the hull – happen during the launch. At this point, the superyacht will be referred to as 'she'.
Sea trials
Now, the performance of the superyacht needs to be verified. Equivalent to a test drive on a car, sea trials will involve towing the superyacht out to the nearest open water, where her seaworthiness, safety systems and speed can be tried and recorded. For Dutch yards, sea trials are completed in the North Sea, which straddles the Atlantic Ocean and the Norwegian Sea, and is known for its rough and challenging waters. If a yacht can handle the North Sea, she can handle most regions! Depending on the results, the superyacht may then undergo some final outfitting works ahead of her delivery.
Delivery
The big moment. Once a superyacht has left her builder, she is considered delivered and is free to cruise wherever she wishes. The owner may be present for this stage, though sometimes only the captain and crew are on board to deliver the superyacht to the owner in another country.
Maiden journey and beyond
The maiden journey is the first voyage made (and destination reached) by a superyacht once she leaves the shipyard. The new build will usually undergo warranty checks within the first 12 months of cruising, to see if any final tweaks need to be made.
Some noteworthy maiden journeys
The 122-metre Lürssen superyacht Kismet, Scotland
The 127-metre Oceanco sailing yacht Koru, Mallorca
The 118-metre Feadship superyacht Launchpad, St Maarten
Decommissioning
There will be years, decades or close to a century between a yacht's maiden voyage and this stage. A lifetime of adventures, far-flung destinations and even different owners will eventually culminate in the end of a superyacht's life. This can happen through disaster – such as a fire or collision – or years' worth of disrepair, which means a yacht can no longer cruise safely. Sometimes, untenable yachts will be repurposed into museums, gift shops and other curiosities, as seen with 117.3-metre Galeb and the "trailer park superyacht", Caritas. This stage can be delayed through regular maintenance, refits and even rebuilds in particularly dilapidated cases.
For more expert superyacht tips and essential yachting advice, explore our latest yacht advice guides.