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Come sono costruite le Hallberg-Rassy


How a Hallberg-Rassy hull is built

At Hallberg-Rassy Marinplast AB, an affiliated company owned by Hallberg-Rassy AB, all Hallberg-Rassy hulls are made. No other hulls are built here. The plant is located in Kungshamn, about one hour drive north of the yard. We will here follow how a hull is laid up.


This is what the mould to a hull looks like. The outside is reinforced with strong metal stringers. The inside has a high glossy finish. The mould is made in two parts, which allows us to build the hulls with an integrated rubbing strake on the hull and a deep bilge. This would not be possible if the mould was built in one part.


The hull is laid up from the outside and in. We start to mask the part of the hull that will be blue. The inside of the mould is black. This makes it easier to see where you have put on white gelcoat.


The gelcoat is based on isophtalic resin. The isophtalic resin is very resistant to water penetration and kkeps its glossy finish very well. The white gelcoat is sprayed on. White for the hull and blue gelcoat for the Hallberg-Rassy stripe. A vinylester based barrier coat is applied. This makes the laminate more resistant to water penetration, and at the same time it protects against print through, which is if the glass fibre is visible in the surface finish.


Compared to the single skin hulls in the old days, today’s hulls are insulated, which means a superior torsional stiffness of the hull.


The material used is a PVC foam called Divinycell. It is fitted when the laminate is still wet, and then covered by laminate. The Divinycell is a superior material for a cruising boat, compared to balsa. The PVC foam has closed cells, which means that the material does not absorb water. The Divinycell will finally be covered with more laminate.


The stern with the integrated bathing platform is made separately.


The parts of the hull are laminated together before the mould is opened. The points where the parts are put together are laminated so carefully that this will be the strongest part of the hull.


The decks are built in the same way as the hulls. Divinycell used as a core material and strong backing plates that are laminated into the deck under deck hardware.


All laminate is carefully rolled out by hand. Temperature and humidity is strictly controlled during the process and registered together with batch numbers, start and stop times, employee numbers and so on in a log book.


The grid system is an advanced design that reinforces the hull under the waterline. The grid distributes loads from the bottom out in the hull in case of grounding. There is a steel beam moulded athwartship under the mast support to carry the strong loads. The grid will also be the support for the floorboards.


The rudderpost is made of solid stainless steel.


The shaft is laminated into the rudder, forming one solid, very strong unit.


The grid is bonded into the hull.


A metal frame is used when the bulkheads are laminated to the hull.


All bulkheads are laminated from both sides, which gives additional strength.


Deck and hull are laminated together. This is made from the inside. This gives a superior torsial stiffness and cannot leak. The coaming between hull and deck is covered by a beautiful teak toetrail. On centre cockpit boats,  the rods for the stanchions will be fitted into the solid coaming. The bulkheads are laminated to the deck from both sides. The inside of the hull is painted twice with topcoat.


The hull is now ready for transport to the yard in Ellös. All hulls are trucked to the yard. All equipment like tanks, engine and joinery will come down through the companion hatch. Everything that goes down in the boat can go out without having to take the boat apart.
To see more images, please go here

Construction details

Hallberg-Rassy is located on the Swedish west coast, 100 km north of Gothenburg. The nearness to the North sea, one of the roughest seas in the world, is easy to see in our boats. They are all constructed to stand against the worst weather conditions. These special details on a Hallberg-Rassy make a whole lot of difference when you are out at sea.
A Hallberg-Rassy is also constructed to live in. You should have almost the same comfort in the boat as you have at home.
How to find out what is good and what is not ? Well, there are three good ways:

  • Go out sailing and test the boat at the North sea by your self and see how things work.
    At Hallberg-Rassy we do…
  • Live in the boat for a longer period of time, to see if the solutions work.
    At Hallberg-Rassy we do…
  • Listen to what our customers say.
    At Hallberg-Rassy we do…

We believe that if we are not satisfied with a solution, you will not be either. The boat must also be tested by real people – in real life, and not just by a test group that does not see the issues that will arise when you live in a boat for a longer period of time. We sail many thousands of nautical miles ourselves.

Here are some examples of the construction details on a Hallberg-Rassy.


This interior layout gives an unimpeded passage from one end of the boat to the other. There are two “clear” areas provided – the galley, where food can be prepared in comfort, and the navigation position with its chart table. The navigation position is adjacent to the large engine compartment which is fully insulated and contains not only the powerful engine, but also all accessories, pumps etc. The compartment is arranged for easy access to all the equipment.


The GRP hull is reinforced with a grid structure at floor level to give it increased stiffness.


The keel is attached to the hull by stainless steel bolts that are highly resistant to corrosion. Positioned above the keel are the large fuel and fresh water tanks (HR 37-HR 64).


The cleats are well secured with four bolts to the cap rail at the outboard edge of the deck, leaving the inboard area clear for safe movement about the boat by the crew.


The keel is cast in lead to enable the keel size for a given weight to be kept moderate, so improving the boats performance. Lead is also softer in case of grounding. There is a deep bilge.


The rudder is suspended on good bearings and its design enables it to be unshipped easily


The mast is carried through the cabin to the keel by a stable support from the deck down to the keel. The chain plates are secured to the insulated hull through guides that are inclined so that there is no change of angle throughout their length.


A luxury shower unit with floor grill for drainage is fitted in the bathroom. The water goes to a reliable and safe pump (manually controlled) directly over board to ensure that water cannot enter the rest of the boat.


Forward, the chain locker is arranged for self stowing – a design arrangement introduced in 1978 – while the electric windlass has its motor mounted below deck to avoid condensation.
This space also provides an area, with drainage grill, for stowing “wet” items such as fenders.


The galley is seagoing and everything is within easy reach. There are also many handholds.


Stanchions are securely mounted, from 37 ft on the bulwark, to provide a clean deck.