The refit legacy

ONBOARD takes a look at how shipyards are shaping the existing fleet while balancing pipelines, innovation and greener credentials…
Words: Gemma Harris

 
Regardless of age, each yacht undergoes transformation through refit, ranging from necessary maintenance and system overhauls to complete redesigns and aesthetic upgrades.
From yachts barely a year old completing warranty adjustments to decade-old yachts requiring extensive modernisation, refits represent more than just repairs – they are interventions that breathe new life into the fleet.

A range of factors currently characterises the yachting landscape: an expanding and ageing global fleet, rapid technological evolution, emerging market dynamics, and an unprecedented focus on sustainability, so shipyards naturally find themselves at a pivotal crossroads.

Today, these refit yards are not just responding to demand but actively reshaping the sector’s future, adapting to strive to meet opportunities and challenges. Expansion is happening, not just in physical infrastructure but also in capabilities, expertise, and environmental consciousness. Each refit is becoming more than just a project but a statement about the future of yachting, a renewal of legacy.

ONBOARD explores the strategic developments at play within various shipyards, spanning from the Netherlands, UK, Spain and Portugal to Greece and Turkey, as well as the visions for the future.

HANDLING THE UPTICK
Across the board, the industry is experiencing a dynamic period, turning the refit space to strategic expansions and facility upgrades to meet growing needs. Increased lead times for new builds have redirected focus toward refit solutions, prompting yards to invest significantly in infrastructure and technological capabilities.

KRM Yacht
KRM Yacht

KRM Yacht, in Turkey, is one of the many that has expanded, with a notable €4 million investment in its facility improvements. “We’ve recently expanded our 2000 metre square interior workshop with cutting edge technology,” Burak Nergiz, communications and media manager, reports, highlighting the addition of advanced machinery, including CNC machines, laser cutting, and other tools. The shipyard’s vision extends beyond current capabilities, with plans to develop a complex to accommodate some of the largest yachts and upgrade the recreational amenities offered to crew.

In the Balearics, STP Shipyard is undertaking an ambitious €8 million expansion project to dramatically increase its operational capacity. As Joan Rosselló, the Palma-based yard’s general manager, explains: “Top-tier infrastructure is essential to maintain a competitive edge.” The shipyard will expand from 130,000 metre square to 162,000 metre square, including the creation of five additional berths accommodating yachts up to 110 metres. Rosselló notes the strategic importance: “Over the years, we have received requests for moorings we couldn’t previously accommodate. With few berthing options for 100 metre plus yachts in Port of Palma, we believe these new moorings will be in demand.” The economic implications are promising; STP estimates the expansion – when completed in spring 2025 – will generate an additional €50-60 million in annual industry turnover.

 

Pendennis
Pendennis

Pendennis has also opened the purse strings by investing in enhanced technological capabilities. The UK-based shipyard recently enhanced its digital manufacturing centre in Falmouth. The facility integrates advanced CNC cutting, profiling, and machining equipment with existing 3D scanning and design capabilities, highlighting a focus on advanced technology.

While Portimão Shipyard continues its expansion, adding 5000 metres square to its already vast 38,000 metre square portfolio of space. It now claims the largest travel lift in Portugal and the only facility in Portugal with the capacity to service superyachts, lifting those up to 300 GT with a 9-metre beam.

The superyacht marina and shipyard based in the Costa Blanca, Portdenia Shipyard now boasts a 300T travel lift capable of lifting 60-metre yachts. Last September, the Spanish yard completed various expansions and upgrades, totalling the workable areas to 50,0030 metres square. Meanwhile, KRM Yacht has simultaneously enhanced lifting needs with a 900-tonne travel lift, enabling the management of larger projects. In Greece, Atlas Shipyard boasts Europe’s largest retractable travel lift, with a capacityof 1200 tonnes.

Others, such as KM Yachtbuilders in the Netherlands, have ensured the facilities are “optimised” to handle future projects. Last year, the yard overhauled its paint shed, and Jildou Huisman, sales and event manager, comments on the future: “There are plans on the drawing table to expand our main shed to accommodate more projects being built at the same time.”

 

Balk Shipyard
Balk Shipyard

Evan Kortmann, CEO at Balk Shipyard concurs “We have agreed on plans with the Dutch government to establish a new marina and yachting centre very close to our current shipyard. This investment will provide a perfect hub for yachts in need of refit or maintenance work. It will also result in Balk Shipyard tripling in size.”

AHEAD OF THE PACK

While these recent equipment acquisitions and expansions underscore the sector’s commitment to capacity, success is about more than just infrastructure; it is about expertise, innovation, and a commitment to excellence. In this competitive space, shipyards are working to distinguish themselves through more than just physical expansion to enable more and bigger projects – they are aiming to improve industry standards and enhance quality through various approaches.

For KRM Yacht, maintaining high standards while managing multiple projects is a priority. The yard’s recognition as the only refit facility in Turkey to hold three ISO certifications through LRQA helps set them apart. Nergiz explains: “This distinction assures clients of our commitment to industry-leading standards.”

With expanding facilities and a growing project pipeline, the yards face an ever-increasing need for specialised professionals. The majority of shipyards around the world now have a dedicated sector or team for refit projects, highlighting the importance of having the expertise to continuously maintain, repair and improve the existing fleet.

 

Atlas Shipyar
Atlas Shipyard

Atlas Shipyard in Greece takes an in-house approach. Highlighting a service portfolio spanning electrics, engineering, hydraulics, carpentry and interior design, they say their strategy goes beyond technical capabilities, “ensuring the highest quality of works and services in a timely and profitable manner.”

This demand extends beyond traditional in-house, pushing yards to develop flexible workforce strategies to accommodate multifaceted projects. Some are addressing this through strategic partnerships and outsourcing.

Albert Morell Olivé, general manager at Portdenia Shipyard, says: “We have expanded our team with skilled professionals who maintain the highest standards, no matter how busy things get.” The yard has also built a strong network of trusted partners and subcontractors. “We have the flexibility to handle more projects without compromising on quality, as we can rely on experts in specific areas when needed,” he adds.

STP echoes this sentiment, and Rosselló comments: “A qualified workforce is essential to meet the highest standards the sector needs. It is also directly linked to the growth of projects, and a trained, efficient and reliable workforce generates confidence in clients.” As well as impacting business competitiveness, a highly trained workforce, according to STP, fosters healthy competition between subcontractors, driving them to raise standards. Both STP and Portdenia also facilitate an open shipyard model, offering clients the flexibility to bring in their own subcontractors.

While physical investments are being made, the availability of enough skilled labour for refitting lurks in the background. Pendennis is taking a forward-looking approach to talent development, with plans to welcome a new intake of apprentices next spring. The yard has been running its programme for over 25 years. “Young people are the talent of tomorrow, allowing us to develop and grow,” asserts Toby Allies, group managing director, demonstrating a commitment to long-term industry growth and innovation.

 

STP Shipyard
STP Shipyard

Strategic collaborations are also proving important. In addition to improving its facilities to meet client expectations, STP also cites its connection with other companies of the IPM Group as an advantage, offering a broader service portfolio, such as the Valencia project. “With this new venture, we aim to replicate and enhance the success of flagship facilities while adapting to the demands of the Valencia region,” explains Rosselló.

RESPONSIBLE REFITTING
As the wider industry is becoming increasingly attuned to environmental considerations, shipyards must also prepare to meet growing demands and anticipated regulations for more sustainable upgrades to stay ahead. While much attention has been directed toward new builds with better environmental credentials, the industry is increasingly acknowledging the environmental potential of the existing fleet. As regulation creeps in and more justified pressure from industry outsiders, there has never been more motivation for shipyards to improve both the fleet and their processes, intending to prevent potential regulatory bottleneck situations down the line.

Kortmann says, “At its core, a refit or rebuild is a more environmentally conscious choice than building a new yacht. It’s an example of upcycling – breathing new life into an existing vessel rather than starting from scratch. Some of our clients are particularly focused on upgrading their yachts to meet higher sustainability standards, and Ursus is a prime example.

By extending her to 30 metres, we have significantly enhanced her seakeeping capabilities and overall efficiency. Additionally, we have equipped her with a state-of-the-art hybrid Veth propulsion system and laid her decks with 100% FSC-certified teak.”

“There’s a notable demand for rebuild and eco-friendly refit projects,” comments Nergiz. “Where owners prioritise sustainable and environmentally conscious upgrades for their yacht.” KRM Yacht is looking ahead, as he adds: “In the coming years, yachts built with hybrid and alternative fuel systems will require specialised refit services, and we are preparing to meet these demands, ensuring our team and facilities will be ready to handle eco-friendly upgrades as they become more prevalent in the industry.”

Portdenia Shipyard.Portdenia also acknowledges this need to stay updated with the latest advancements in sustainable technologies to support refits. “This includes preparing to implement more efficient or eco- friendly propulsion systems and energy-saving upgrades, helping yacht owners align their vessels with the industry’s move toward sustainability,” says Olivé. “For us, we’re convinced that the industry’s future has to be sustainable. We’re working on making our operations more eco-friendly step by step – whether that’s by using cleaner energy, improving how we manage resources, or looking at ways to reduce our overall impact. It’s a process, but we know every change we make helps,” he adds.

 

Portimão Shipyard
Portimão Shipyard

Portimão Shipyard envisions a technological evolution toward more sustainable solutions onboard. Ricardo José, operations director of Portimão Shipyard, notes: “Hybrid and electric technology are promising, but in my opinion, hydrogen will be the future.” Their forward-looking approach is matched by a comprehensive environmental management strategy within the yard, including waste management, eco-friendly equipment, and intelligent consumption systems for yachts housed throughout a project. Atlas is similarly taking a holistic approach, aiming to expand the shipyard’s exposure to a yacht’s life cycle, including experimenting with hull shapes, propulsion designs, and alternative fuelling options.

However, while pledges and change are good, challenges remain for the industry. KRM Yacht acknowledges the hurdles. “The transition to environmental sustainability is met with challenges, such as high costs for alternative fuel systems and limited infrastructure for hybrid or electric yachts,” Nergiz says.

 

Portdenia Shipyard
Portdenia Shipyard

Olivé from Portdenia is in agreement and says: “Adopting technologies like alternative fuels, hybrid systems or more sustainable operations require significant investment and expertise.” The shipyard emphasises that while sustainability is becoming more of a reality, there is still a long way to go before sustainable technologies become standard across all yachts. KM Yachtbuilders also recognises that true sustainability is a long-term game; Huisman explains: “We focus on practical solutions like lightweight designs, advanced hydrodynamics, and hybrid systems that can be implemented today while laying the groundwork for future innovations.” The shipyard already uses recycled aluminium, sails, upholstery, bio-antifouling, and hybrid propulsion and explores other green technologies to minimise its ecological footprint.

TECHNOLOGY-LED PROJECTS
Alongside the promise of greener refitting credentials, the shipyards agree that technology has emerged as a critical tool for the sector. As Olivé notes: “Balancing cutting-edge and eco-conscious technologies will make yachts more dynamic and capable than ever before.”

Shipyards are implementing advanced technologies to overhaul maintenance, design and operational efficiency. Predictive maintenance systems now provide data-driven insights that can extend yacht lifecycles, offering better management. While digital connectivity, Artificial Intelligence (AI) and enhanced automation are no longer concepts of the future but becoming the norm, reshaping the operational landscape. A specific tool reshaping the refitting sector is digital twin technology, which creates virtual representations of yachts. Transforming the traditional refit approach can enable engineers to validate design changes and complex refit scenarios.

IBC Shipyard
IBC Shipyard

KM Yacht Builders
KM Yacht Builders

Marina Port Valencia
Marina Port Valencia

WHAT NEXT AND WHERE?
When it comes to the future, new opportunities in different regions are coming to the fore. The Eastern Mediterranean has been gaining popularity, the Middle East has also had a noticeable surge in recent years. As the wider industry develops and expands into new regions, consequential demand for refit services worldwide will begin to increase.

The refit sector goes beyond a support service; it is a critical driver of the industry’s future. It isn’t just about the upgrades but elevating industry standards, enhancing environmental credentials before regulation hits home, and aligning with changing owner and industry preferences – a future of lasting legacies being rewritten one refit at a time.