A Visit to the Hanse Boat Yard
a visit behind the scenes at the hanse boat yard
At the start of this year, the Inspiration Marine team took a trip to the Hanse yard at both Greifswald in Germany and Goleniów, Poland to learn more about the production process. It was a fascinating experience to see how raw materials are transformed into the yachts that arrive with us, ready to be commissioned for their new owners.
from concept to winning designs
Hanse are one of very few boat builders in the world who can create a boat almost entirely “in house”. The naval architecture specialism is outsourced but after that every other element of the systems engineering, including one of Europe’s largest 5 axis milling machines for plug building, mould making, furniture design and build, hull and deck lamination and final build is ALL completed by Hanse.
the showroom at greifswald
Visitors to the shipyard at Greifswald are able to step aboard a selection of Hanse models in the impressive showroom.
Sheltered from the elements and open all year round, this presents a private 'boat show' style lineup of key models from the Hanse, Dehler, Moody and FJORD brands alongside each other.
hull moulding
One of the most impressive aspects of the whole build process is the hull moulding. We were lucky enough to have the tour conducted by Gregor Bredenbeck, who is the head of production, whilst also being a Masters lecturer in GRP boat building.
Each hull is made up of multiple fibreglass matting types and weights, which are all CNC cut and numbered to follow a detailed lamination schedule. This ensures that the stresses and load paths that the hull is subjected to through its life are handled in the most effective way. Additional barrier layers are installed where bulkheads are present to eliminate them becoming visible on the outside, areas where there are skin fittings are de-cored to prevent crushing and structural elements like rudder stock tubes are additionally re-enforced. Unlike a lot of boat builders, Hanse also take the time and effort to ensure that each bulkhead is fully laminated to the hull. This is one of the key elements which gives a Hanse the renowned strength and stiffness.
engineered for strength
Hull mould with gelcoat.
Hull with fibreglass lamination.
vacuum infusion
When the bulkheads get to a certain size it becomes a strength requirement to make them using a vacuum infusion process. This is where the layers of fibreglass are laid into place dry (without resin) and then the resin is pushed through the layers using a vacuum system. This process ensures that the resin consolidation is exactly the correct level without adding unnecessary weight.
cabinetry and woodwork
Almost unique to Hanse Yachts is the ability to build all furniture elements in house from scratch. There are a number of benefits to this in terms of build efficiency, they do not need to wait for an external supplier to deliver the furniture for each boat and as the furniture is not being transported there are much fewer opportunities for damage. Should any pieces be damaged during installation, a replacement can be ordered and made very quickly and efficiently only 50m from where the build process is taking place.
An entire forward cabin, galley, saloon side or aft cabin is built separately from the hull, which makes the installation of lighting, domestic appliances. blinds, electric sockets etc much easier than trying to do so with the furniture on the boat, not to mention again fewer opportunities for damage.
Quality at every stage
Once the hull and deck are moulded and the furniture elements are built, it is time for the yacht to pass through the build process. Initially the tankage and plumbing systems are installed, followed by engine and electrics.
Once this equipment is in place, the furniture modules are lowered in and then the deck installed. At each stage a quality control “gate” ensures that any issues are raised early in the build process and rectified before it becomes difficult to do so. The culture in build process also ensure that the builders are happy to raise issues they see as they appear.
the deck and the "marriage"
Building the boat without the deck installed on the hull make the process much easier and far more efficient.
Once the interior systems and furniture are on place it is time for the “marriage”, which is one of the last parts of the build process.
a perfect match
Due to the accuracy of Hanse’s mould making processes, the hull and deck fit together beautifully. This gives the boat builders another opportunity to add rigidity and strength to the hull structure.
Much like the keel installation, the hull is both chemically bonded and mechanically joined by each and every stanchion base, mooring cleat, genoa track other deck fitting.
final inspection
After the numerous quality gates throughout the build comes the final quality inspection, which checks through each and every aspect of the build and inventory prior to being ready to dispatch to the supplying dealership.
transport
When ready to leave the shipyard, the yachts are loaded to specialist lorries to head for their commissioning destination. The dealership is then responsible for the commissioning process, which includes everything from rigging and antifouling, through to extensive systems checks and sea trials, prior to cleaning and detailing ready for handover to the lucky new owners.
If you are interested in visiting the Hanse yard at Greifswald, please get in touch with us to learn more.
