By Taylan Salgür, Business Development Director at Turquoise Yachts
Yacht construction is becoming more complex and time-sensitive. As vessel sizes increase and customization grows, traditional production methods are under pressure, especially in labor-intensive stages such as fairing and surface preparation. These processes remain critical to final quality but are increasingly difficult to scale.
Production efficiency is now a key factor in a shipyard’s ability to deliver consistently, manage capacity, and remain competitive.
Scaling Production Without Compromising Quality
As demand for larger yachts grows, shipyards are reassessing resource-intensive processes. Fairing has traditionally relied on skilled manual labor. While effective, it requires significant time and workforce investment.
At Turquoise Yachts, fairing a yacht typically required 9 to 10 months under optimal conditions. This created a clear constraint on production timelines and capacity.
Training specialists takes time, and maintaining consistency across large hulls becomes more difficult as projects scale. Across the maritime sector, these pressures are driving interest in automated and controlled application technologies, supported by companies such as AkzoNobel.
From First Trial to Implementation
We began exploring spray-applied fairing during the Covid period, when operational constraints made efficiency even more critical. The first on-board trial took place in August 2020.
Initial training was conducted over three days with the material supplier. This was followed by continuous application across different sections of the yacht over the course of a month. This extended trial phase allowed teams to adapt to the process while validating performance under real production conditions.
After these early stages, the system was gradually introduced into active projects.
Controlled Application Improves Consistency
The spray-applied fairing system, developed with AkzoNobel under the Awlgrip range, combines automated application equipment with advanced filler materials designed for consistent performance.
Compared to manual methods, spray application ensures controlled mixing and uniform distribution across large surfaces. This reduces variability and limits defects such as air entrapment and uneven thickness.
Environmental conditions can be managed more effectively, supporting consistent curing and reliable adhesion. This results in more predictable surface quality across the hull.
Efficiency Gains Through Process Optimization
The impact on production timelines has been significant. Fairing duration has been reduced from 9 to 10 months to approximately 7 to 8 months, depending on project scope and conditions.
Internal benchmarking across projects also showed a 30 to 40 percent reduction in labor hours during the fairing phase. Process efficiency improved by around 30 percent due to faster application and more consistent output.
These improvements allow for better planning, reduced bottlenecks, and increased overall shipyard capacity.
Integrating Technology with Skilled Work
Automation is improving parts of the fairing process, but skilled labor remains essential. Complex geometries and detailed areas still require manual finishing.
Adopting new technology requires training and adjustment. The transition from initial training to full application takes time, particularly when integrating new methods into ongoing projects.
At Turquoise Yachts, the focus has been on using technology to support skilled teams and improve consistency without disrupting established quality standards.
Building More Reliable Production Processes
As projects become more complex, production reliability is increasingly important. Shipyards need to manage variability, maintain quality, and scale output.
Spray-applied fairing introduces greater consistency into a traditionally variable process. Controlled application reduces rework, improves planning accuracy, and supports stable production.
This allows shipyards to maintain performance as workloads increase and project requirements evolve.
From Process Improvement to Industry Shift
The adoption of spray-applied fairing reflects a broader shift in yacht construction. Fully manual processes are becoming less practical for certain stages of production.
Shipyards that adopt controlled application technologies can improve efficiency, maintain consistent quality, and increase capacity without proportional increases in labor.
This shift changes how craftsmanship is applied, combining technical control with skilled execution.
Looking Ahead
Advances in materials and application systems will continue to shape yacht production. Their role in improving consistency and efficiency will grow.
The focus remains on delivering high-quality vessels while managing increasing complexity. Shipyards that adapt will be better positioned to meet demand and maintain standards.