Hall Spars complete giant mast

Hasso Plattner's 147ft Baltic maxi nears completion

Thursday August 8th 2002, Author: Hall Spars, Location: United States
Hall Spars & Rigging has just completed the longest carbon-fibre mast ever built in Bristol, Rhode Island. The carbon-fibre mast stands 182ft tall and is currently being shipped to Finland. (The distinction of the longest mast built in Bristol belongs to Herreshoff Manufacturing, which delivered the 196-foot steel spar for Reliance in 1903.)

The Hall carbon mast is for SAP boss Hasso Plattner's new Baltic 147, a light-displacement, high-performance sloop constructed of carbon fibre and designed by Reichel/Pugh. Nearly every system on the yacht is custom-designed, with weight savings and high strength in mind.

"From concept to finished product, Hall Spars & Rigging never lost sight of the high-performance goal," says Eric Hall, president of Hall Spars & Rigging. "In addition to the tube, everything attached to it has been optimally designed for this particular yacht."

The carbon elements of the mast, including the spreaders, are of high-modulus carbon fibre. This material is banned in the America¹s Cup. Hall's in-house engineering staff conceived this high-performance design using such advanced analysis tools as Finite Element Analysis and solid modeling. "The result is a weight- and cross section-optimized mast and rigging package that will maximise the speed potential of this advanced new yacht," says Hall.

High-performance starts with Hall's unique construction process. The carbon tube is seamless pre-preg carbon is carefully laid up over a male mandrel to precise engineering specifications. The carbon is then fully autoclave cured to 121 degrees C and 6 bar pressure. (The mandrel is removed upon curing.) Hall is the only company using the seamless, mandrel-molding process for spars of this size.

The rig is fractional, but only just. There are 1.5 meters of mast above the headstay attachment. The rig has four sets of adjustable spreaders, swept 23
degrees. The backstay is Kevlar, and the mast step uses 2 x75T hydraulic rams to tension the rigging. In addition to the main, spinnaker, genoa,
staysail, and trysail halyards, the boat is rigged for the new "Code 0" headsails.

The ship carrying the mast should reach Finland in mid-August. The Baltic 147 is expected to begin sea trials in late September.

Hall Spars & Rigging is provider of spars to Alinghi, Swiss challenger for America's Cup 2003. Hall is currently building superyacht spars for the Farr
115 and Wally 80.

Baltic 147 Mast Construction Summary

Length: 182 feet (55 meters)
Weight: 6,000 lbs.
Construction: High-modulus carbon fibre, mandrel-molded, seamless tube, autoclave cured at 121 degrees C, 6 bar pressure
Configuration: Slightly fractional (1.5 meters above headstay), four sets of adjustable spreaders, hydraulic adjustable mast step, carbon tailfairing added to mast track to facilitate roller furling mainsail. This is a semi-monocoque structure in carbon fibre and honeycomb core. (Roller furling carbon-fibre boom supplied by Rondal.)
Rigging: Hall installed the standing and running rigging, including all splicing and fitting, custom rod rigging from Ocean Yacht Systems, including titanium turnbuckles and tip cups, split backstay constructed of Kevlar fibres, custom running rigging from Samson Ropes, including Vectran-and Dyneema-cored line with Dacron covers, a total of 6,562 feet of high-tech line was used in the running rigging, with the longest piece the 394-foot main halyard

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