Aglaia, a 77ft 15-year old yacht designed by Rob Humphreys, was sold by Berthon in the autumn of 2015. The new owner wanted her refitted and modernised; accordingly, a delivery crew brought her north to Berthon’s Lymington Shipyard in October 2015. This is the story of her comprehensive restoration, a project that spanned just 9 months and was completed entirely at Berthon.
After stripping the interior for bulkhead and headlining refurbishment, it quickly became apparent that Aglaia, which has already done three circumnavigations, could benefit from input from Berthon’s Ross Monson – an experienced yacht captain and large yacht refit manager – who was assigned to the project from the outset. As with any substantial refit work at Berthon, Aglaia then underwent a comprehensive assessment prior to the project plan being consolidated and put in place.
This included substantial deck, rig and rigging, electrical, electronics, engineering and hydraulics systems surveys and a full de-store process that lasted 3 weeks. Every item removed was put into an inventory database, logged, photographed and stored. The main areas identified for work were: mast shot blast and painting; hull, coach roof and coamings paintwork; teak deck replacement; full interior refit; new rigging and sails; and marine engineering – motors and pumps, electrical, fridge/freezer and air conditioning systems and new electronics.
Berthon employ over 150 full-time skilled staff (including over 20 project managers and 25 apprentices) and as such comprehensive labour allocation plans across all trades jobs are worked up from the outset (and constantly tweaked) to ensure a seamless refit, with maximum efficiencies. Lean management techniques applied by Berthon Project Managers allowed us to average just over 450 hours per week peaking at 900hrs per week to attain maximum productivity on and off the yacht. The standing rigging was inspected on 28th October with the mast unstepped and all fittings removed for shot blasting and subsequent painting. Aglaia was then lifted to Berthon’s M-Shed where preparatory work began immediately, making the yacht safe for work ashore.
Here, hatches, winches, tracks etc were lifted in preparation for removal of the teak deck. A good deal of cabinetry and all headlinings, cabin sole boards and other interior fittings were removed or stripped back so that basic systems could be accessed and the necessary re-engineering work carried out. Fixed floorboards were removed in the galley and crew quarters to improve access to fridge motors, air conditioning systems and pumps. All the tanks were emptied at the outset, pressure tested and cleaned.