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The 335m x 60m drydock at La Ciotat is currently being sub-divided to create greater efficiency and lower rental costs

Technical revolutionBased in a former French

shipyard, refrt specralistCompositeworks has increased

turnover by investingin equipment for larger and

rnore compLex projectsJAKE KAVANAGH REPORTS

ounded in 1998, the yacht refitcompany Compositeworks has

recently completed its 800th

refit, and at the end of March

2016 will report turnover of€40rn, an increase of20 per

cent on the year before. Much ofthis success

has been due to the rise in the number ofyachts seeking upgrades and modificationswith a proven superyacht yard - especially as

Compositeworks is also based beside some ofthe most versatile haul-out and maintenance

facilities in the South ofFrance.

With the ability to dry-dock yachts inexcess of200m, the company has recently

built on its reputation by investing heavily innew equipment, and has restructured its

in-house team to become more techno-centric.

The company has also proved highly adept at

tackling some of the most complex refitprojects around - ones which are normaily thereserve ofthe original builders - and has also

become something of a specialist in managing

superyacht extensions, including designing

and retrofitting large swimming pools.

But,t^/hilst focusing on technical excellence,

Compositeworks has also considered the'stranded' crew. Despite being opposite a

thriving tourist town, the company has gone

to great lengths to ensure that visitingsuperyacht crew have all the creature

comforts of home on site. It's a trend that'sgathering some pace in the industry, and

actually helps the speed of a refit.

We Can SCAII a superyacht during the season

- without interruption to its service - and then haveall the components prefabricated ahead of the refit

56 www.suprRyACHTBUS NESS.NET ApRtr 2016

Compositeworks

From ships to yachtsLa Ciotat (pronounced 1a-see-oh-tah) is a

historic town nestled in a wide bay betwee§

Toulon to the east, and Marseilies to the west.

Commercial shipbuilding has been here

since the 13th century, and by the 1950s, the

docks and slipways ofthe Chantier Naval de la

Ciotat (CNC) yard had gror,un out of allproportion to the low-rise town. In fact, theharbour was only just wide enough toaccommodate the newly built ships as theywere launched dolun the slipways, the stern

wave frequently swamping the tourists whohad lined the quayside to watch.

The largest ship ever built at CNC was the162,0009rt tanker Al Rowdatoin, completed in1976 as the yard began its steady decline

against competition from the Far East. This

eventually led to the closure ofCNC in 1988,

which was a major economic blow to the area.

Pierre Tidda, one ofthe 10,000 workersmade redundant, immediately organised a

picket outside the gates, insisting that theCNC yard could once again be a majoremployer in the region. His eight year actionpreserved the mighty shipbuildinginfrastructure, including the giant 550-tonne

Compositeworks has a [arge three-storeyoffice block which has commanding views

across the rest of the facilities

Krupps crane that straddles the largest (335m

x 60m) of the two dry docks.

Tidda's tenacious siege ofthe 34 hectare

(340,000m'z) site resulted in a newly formedorganization called Semidep-La Ciotat beingfunded by the government to create a yacht

repair and maintenance centre. Some €45mwas injected to restore and maintain the vast

infrastructure, and Tidda's vision was finallyreaiized. He is now the manager of a site with700 specialised personnel that refit and

maintain around 600 large yachts a year.

During SB's most recent visit in early 2016,

a further €16m was being spent to improve

the main dry dock facilities, and the local

authority was making a big investment toimprove the roads and promenades. ll[]

ritish-born Rob PaPworthbegan his career with a

degree in navat architectureat SouthamPton UniversitY,graduating in 1995. Aftercrewing and skippering on

high profite superyachts, he joined the UK

composite speciatist Green Marine on thebuitd of the 30m carbon./titanium Leopard

of London, where he met Compositeworks

co-founder Mark Salman, who was theproject's water bat[ast consultant.

ln 2001, Papworth hetped Project-manage two new buitds for the Votvo

Ocean race, then spent six months in

Itaty with the Prada 11A74 & 80 Luis

Vitton Cup project before becoming a

futt-time member of the Compositeworksteam in 2002.He is currentty chairmanof the ICOMIA Superyacht Refit Group,

which he hetped set up, with the aim ofguaranteeing standards of workmanshipand environmentaI protection.

"Since 2011 we have doubled our

turnover, and our figures for this last year

suggest an increase of 20 per cent," he

says. "We think this is because owners are

beginning to put greater trust in the refit

Papworth is a former superyacht skipper

"TechnicaI demands are also increasing,which is why we've expanded ourtechnical team. We now have ].3 projectmanagers and a 1o-strong support team.With repeat clients where we know theboat wet[, we can reduce the time neededfor a refit - and therefore the price.

"lt is stitt highÿ competitive out there,and even post recession, we are seeingdue diligence as customers shop aroundfor quotes. This is stitt not the timeto be raising prices, but instead to be

not the time toinstead to be concentrating on

be raising prices, butbeing more

competitive and technically efficient than our rivals

sector as a whole, particularly when itcomes to major projects, and they want toplace them with [ong-estabtished yards.

"Previousty, if an owner wanted major

modifications done, they would take theyacht back to the builders, but that ischanging. There are now lots of yachtson the market, so owners are buying

them at a good price, then budgeting fora personalized makeover. This has hetped

fuet demand for competitive refits."When it comes to 8Om-plus yachts,

the new buitd yards are pretty futl at themoment, with tittte capacity for refits.So, if you want a new pool or a restyledsuperstructure, you're either going to waitfive years or you're going to modify your

existing yacht. We've therefore seen a lotof growth in the 80m-1"00m range, withmore US owners coming to us for refits.

concentrating on being more competitiveand technicatÿ efficient than our rivats,

which is why we have invested in new

equipment such as the 3D scanner and

associated design software to improveturnaround times by using prefabrication.

"The improved dry dock witt make abig difference to the avaitabitity of deepwater space, and faster turnarounds fordry docking services. lt shows Semidep'scontinued support for the industry.We've been abte to cover the temporaryshortage of space by using yards nearby.

The new infrastructure improvements wi[[

hetp attract new ctients. Meanwhile, theinvestment in our crew lounge and gym

has proved very popular."The future tooks bright, but we must

always stay ahead of our rivals - and

continue to provide fast turnarounds." Etr

APRIL 2016 ] WWW.SUPERYACHIBUSINESS.NET 57

insight

To handte increasingly complex refits,Compositeworks has restructuredits technicaI resource service. Thevarious disciptines are now steeredfrom one department comprising 10managers, and covering the principleactivities of navat architecture,engineering, scanning, technicaIdrawing and marine coatings.The team is assisted by a new 3Dscanner - accurate to within 1mm -which provides the data to attow theprefabrication of components aheadof a superyacht's scheduted refit.

Compositeworks was one of the firstcompanies to be drawn to the potential oftheCNC site, and has since been joined by 34

other marine specialists. In 1998, it leased a

series offormer building sheds, and began tocreate cutting edge sailing craft in carbonfibre, a skill reflected in the company name.This led to new builds for the Volvo Ocean

Race and the America's Cup, and eventually tomuch larger projects, the last being a 30m

catamaran. Although the company still buildsbespoke superyacht tenders, the emphasisnow is entirely on ref,ts.

Compositework's steady annual growth(around 10 per cent) was helped by Semidep's

continued investment in the former CNC

facility. One of the first communal investmentswas a 2,000-tonne synchrolift beside the mainwet dock, using a design originally intendedfor nuclear submarines. Whilst the doc§ardcranes remain in commission, including a

giant Krupps crane ideai for lifting ketches,

Semidep has since added a host ofyachtmovers and travel lifts. The business model is

to continue funding communal infrastructure,and lease it back to the on-site companies.

Whitst much of the infrastructureis communat, Compositeworkscommissioned its own climatecontrolted paint shed, which is parttysotar powered. lt can take craft up to45m, and atlows intricate paint jobsto be carried out atl year round.Repainting has atways been key tothe yard's portfotio, but the emphasisis now moving more towards hutlextensions and other major works.

The exceptions are where a company needs

something for it's sole use, such as the

climate-controlled paint shed Compositeworks

built on site, just a short distance from thehaul out dock. Then the item becomes

self-funded on a long-term 1ease.

Complex refits and major rebuildsWhen SB first toured Compositeworks in early

2012, with the recession stiil largely playingout, the yard was exceptionally busy.

.{

Returning inJanuary 2016, business waspositively booming. We witnessed the majorconstruction works to the dry dock, and the

investment in the Compositeworks off,ces,

which have commanding views over the1.5km of quayside moorings.

The company is very aware that althoughspace for the larger yachts is limited, there is

still plenty of competition, especially in thisarea of the Med. Although Compositeworks

built its reputation largely on its paint f,nishes

and stylish new builds, with their team ofinternational project managers an importantbonus, the emphasis of its work has moved

more towards complex ref,ts and majorrebuilds. For this reason it has restructuredthe project management teams, and begun

using highly accurate 3D scanning equipment

:$&,;5

rü

With new build yards at capacity, ownerswanting modifications are coming to us - they knowwe can do this work to a very high standard

58 www.suprRyACHTBUSNESS.NEr I ApRL2016

made by Florida-based Faro Technologies.

"We believe heavily in peop1e," explainedoperations director Rob Papworth. "We havestrengthened our 100-strong in house teamwith 15 more people, and now have a

dedicated technical office where everydiscipline is represented to give a centrallybased, but multi-faceted service."

This 'technical brain' is headed by

Jean-Michel Arnaud foliowing an internalpromotion, and comprises ten highlyexperienced managers. This includes a

resident naval architect, three engineers, anda paint superintendant, with the rest made upof technicians and draftsmen.

"We know that clients will beneflt fromthis greater technical approach, starting withmore accuracy at the initial quotation stage,"

.ar.tr

§h:

lnstalted by Semidep to supptementthe main dry dock, the 200-tonnesynchrolift has a five-hour turnaround,and gives access to 14 hectares ofreinforced hard standing. The tiftrequires each yacht to drop into aspeciatty-made cradte that can cost upto €400,000 each, but can be storedon site for repeat customers. The tiftwas originatly buitt to handte nuctearsubmarines for the French navy.

Arnaud explained. "There will also be a

reduction in warranty exposure by minimizingthe technical risks ofa major project."

The purchase of a highly portable Faro 3D

Iaser scanner that maps anything from a

specific target area to an entire vessel has

allowed for plans with a tolerance of just1mm. The scans are taken from a number ofpositions, which can help interpretinaccessible areas, and are then uploaded to a

computer. The data is combined to give a

rotatable 3D graphic."The accuracy reduces the need for any

re-working or modif,cation during a newinstallation," Arnaud said. "Another advantageis that we can scan a superyacht during theseason, without interruption to its service,then have all the components pre-fabricated

Gompositeworks

Much of the original structure ofthe CNC shipyard remains, inctudingthe tatt sheds designed by GustaveEiffet, creator of the Eiffel Tower. Thesheer height of the buildings letsCompositeworks haul in large saitingyachts without detaching their keets.Within the buitdings are temporaryand permanent workshops, handtingeverything from meta[ fabricationto advanced carbon composites.The company also makes customsuperyacht tenders, and uses theremaining space for the storage.

ahead ofthe ref,t. When the yacht arrives,

everything will be ready and waiting, and

- most important of all - will be a perfect fit."As a worked example, we saw the 3D

design of an enlarged swimming pool being

developed by naval architect John Stott for the74m Feadship Mogambo. Key to the design

was a clever wave-catching gutter, and a

storage tank deep in the bilge that allows thefive tonnes of fresh water to be used as ballastwhen the yacht was in transit. The tank also

keeps the water f,ltered, and at the correct

temperature for reuse.

"We are doing a lot more swimming poois,

either retro-fitting or enlarging, and have

become quite specialized," Papworth

explained. "With the main new build yards atcapacity, oivners who want majormodifications are coming to us as they knowwe can do this lype of work to a very highstandard. For example, we recently created a

new pool for a 130m superyacht that waspreviously pool-less."

Looking after the crewThe drive for a technical edge has also led toinvestment in the crew and SB was shor,rm thenew crew wing, which was opened in July2014. There is a large lounge, with a bar and

S§-equipped plasma TV on the wa1l, with an

adjoining gym that looks out onto the water.

The lounge also has full lViFi connectivily, and

other home-from-home facilities for ll[]

APRIL 2016 I WWW,SUPERYACHTBUS]NESS,NET 59

1. ! .'.. ,- '"..:ï r;: t.:

The originalgate suffered frommajor leaks at the corners

Paimboeuf buitt a reptacement witha leak-proof wedge design

The new gate wittbe repositionedover the secondary citt in mid-2016

active young people who may find themselves

temporarily homeiess.

"We saw a need for somewhere for theIiveaboard crew to go when the yacht was

inaccessible, such as when we x-ray seams,"

Papworth explained. "The gym has also

proved popular, as today's creurmembers are

more into fltness and Facebook than before.The lounge gives them a breathing space,

somewhere to catch up on emails, and tomingle with other crews. A relaxed andrefreshed crew is a vital element to a

successful refrt, especially as the yacht willprobably go straight back out onto charter."

Compositework's location is popular withcrews anyway due to the proximity to skiresorts, and to the airports ofMarseilles andToulon. Owners can also fly in to a privateairf,eld just 15 minutes away. The company

60 www.suprRyACHTBUSlNESS.NET I ApRtL 2016

employs a full-time crew support manager,

and retains a taxi service with English-

speaking drivers. The bay, with its protected

status and offshore islands, is also a delightfor water sports enthusiasts, and there is

plenty of rentable accommodation in thetown, especially outside the tourist season.

Fixing a dry-dockAlthough the main dry-dock has been a huge

asset for the various companies at La Ciotat, itproved expensive for singie projects, so

Semidep has been working to reduce its size

from 336m to 200m, still 20m longer than theworld's largest superyacht. A new leak-proofdock gate with a 'wedge seal' design was

installed in 2012 by the French civil engineers

CM Paimbeouf, and in January 2016, a new sillwas being made for it further donrn the dock,

lntended for ships onty, there waslittte freeboard between the dockedge and the hutt, making eftectivefendering difficutt. As part of theimprovements, a new, and higherinner wa[[ is being made, which witlmake better provision for yachtfenders, and provide better accessand mooring points. Diver access tothe dock is also being enhanced.

so it can be repositioned. Additionalimprovements include superyacht-friendlysidewalls and a new pumping station to drainthe doôk in just seven hours. AIl the mains

services, including three-phase power, wiII be

availabie to each docked project.

The shorter dock should make it quicker

and more eff,cient for single, fast turnaroundprojects. In addition, it will free up over 260m

ofhighly accessible quayside, all easily

reached by mobile cranes.

Spearheading the transformation is the

CEO ofla Ciotat Shipyards, Jean Yves Saussol,

a fluent English speaker with a vision to make

the yard even more amenable to superyachts."I am striving to implement a renewed and

coherent strategy to take this amazing place

to the next level," he told SB. "The currentremodeling of the dry dock is obviously a

insight

cornerstone ofthis strategy, and our newmotto is 'Something bigger is coming'."

New investors are now being sought forthe onward progress ofLa Ciotat Shipyards,

with long-term partnerships beingencouraged to create yet more marine

opportunities in the area.

Looking aheadThere is no doubt business is booming forCompositeworks, with 112 refits successfully

completed in 2015 alone. La Ciotat Shipyards

As this graphic shows, the dry dockwitt be shortened to 200m afterthe gate has been retocated to thenew citlposition. The wortd's largestsuperyacht is currentty 180m, butshoutd there be demand for evengreater dock space, a new gatecan be made and inserted into theoriginaI position to return the dockto an overatl tength of 335m.

also has the advantage ofbeing abie to handle

some ofthe largest superyachts afloat, eithervia the 2,000-tonne synchrolift or the 200m

drydock, but Papworth is determined not torest on the collective laurels.

"We've come a long way," he said. "This is

thanks our in-house team and their knowhow, and the experience ofthe local

contractors, up to 300 ofwhich we have on

site at any one time. We also have thepowerful tools being provided by La Ciotat

Shipyards to carry out each project. But other

Compositeworks

Accessibte quayside for floatingprojects is highty vatued, especiattyas the harbour has an averagedepth of nine metres, ideatforsailing yachts. By moving the gateback, two lengths of deepwaterquayside of 130m each side wittbereteased, adding to the flexibitityof the facitity. As with the maindry dock, this extra quayside wiltbe furnished with power, data andwater hookups, and wit[ have futlvehicutar access.

yards around the world are also developing

new skills and investing in betterinfrastructure - so, in order to atffact newclients we will have to continue to do the

same, especially on the technical side.

"There are less prime spots for larger

boats, which increases demand, but we are

already competing with three yards in ourarea of the Med which have similar levels ofserviceability and price, so at the end oftheday it's about quality and delivery. A

superyacht yard with a long track record ofsuccessful refits will always be a wise choice."

By way of a conclusion, Papworth indicatedthe most recent refit, the 30m Inace explorer

yacht Zulu which had just received a hullextension and full interior reflt. The use ofthe3D scannêr allowed for pre-fabrication of thenew transom, so the whole reflt was

completed in a tight three month time scale.

"We were able to accurately price this job

from the start," Papworth explained."Combined with improved efhciencies and

reduced time scales, we reckon that it can nowbe possible to increase the resale value ofsome yachts beyond the outlay ofthe reflt. Ifso, that is the Holy Grail ofour industry." Etr

Improved efficiencies and reduced timescales mean it's now possible to increase the resalevalue of some yachts beyond the outlay of the refit

d mrcx ouR sHoRT video ofRob Papworth giving a guided tour around

Compositework's new facitities in La Clotat

www. yo utu be. c om / user/ SYB Ma ga zin e

APRIL 2016 ] WWW,SUPERYACHTBUS NESS.NET 61

insight Compositeworks

rypifyingthqkirld of extensive projects

Compositework§.undertakes is the68.?m Feadship'Èalcon Lair. Built in1983, tùe yachiwas originally named

llorizon L, and then later becam e llÿhite

Cloud. Gômpositeworks had workedon her several times prior to her major

transformation to a redesign by Briüshnaval architects Olesinski Ltd.

The work involved a total remodellingacross every deck, and a 3m hultextension. Also added were modificationsto her wing stations, bulwarks and thebuilding of a lm sheerline to the bow.

The final touch was a full hull repaint in

blue and white before she was delivered

in August 2015. She has since been putforward for a world superyacht award.

WorksMajor interior and exterior modificationSystems & equipment upgradesDry dockingDry docking, modifications and repaintDry docking, maintenance and repaintDry docking, modifications and PaintDry docking, major engineering modsDry docking, major modificationsDry docking, repaint, structural modsMajor modificationsDry docking, major speciaI surveyDry docking, machinery upgrades, teakDry docking, machinery upgrades, repaint

!-J""

Compositeworks reports compteting a total of 112 refits in 2015, with turnoveracceterating from a steady 10 per cent year-on-year growth to 20 per cent for last year.

The size of the yachts, and the comptexity of the refits, is also on the increase. Here is a

snapshot of some of the most recent projects, listed in descending order of size:

MakeLurssen

Lurssen

Lurssen

Feadship

OceancoNobiskrugTrinityFeadship

AmetsPerini Navi

CRN

Attoy

Perini Navi

LOA

l40mL25m115m90m80m75m75m7Om

65m65m60m55m55m

Power/sailPower

Power

Power

Power

Power

Power

Power

Power

Power

Sait

Power

Jdil.

Sait

2,000-tonne synchrotift200m drydock300 tonne travel hoist66O-tonne mobile crane1.7km of deepwater quayside

Wide range of mobite cranesl4 hard standing stotsWide skitts base of subcontractors

45m paint shedLarge storage capacity115 full-time staffl0 member technicaI teamFutt-time navaI architect13 project managersFut[ range of workshops forwood, metaI and compositesExtensive rigging, etectricaI and

mechanicaI servicesComfortabte crew lounge and gym

Specia[ist 3D scanning

46 Quai Francois MitterandBoite Postate 2001513703 La CiotatFrance

) Emait: info@compositeworks.com) Web: www.compositeworks.com)Tel:+33 (0)442 838300

Owners want [arger pools, so Compositeworks has become expert at building and installingspil[-proof designs that store water in a deep, temperature-controlled tank when underway

62 wwwSupTRyACHTBUSTNESS.NET ApRL2016

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