Catamaran Orange. Commando operation at the Multiplast boatyard
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Since Saturday February 16th, the day Orange's mast came into the boatyard's workshop after it broke at its top section, a whole team was set up in order to carry out the repairs promptly.
While some of the technicians were busy cutting and preparing the moulds for the top part of the mast, Patrick Cissé, in charge of the purchases at Multiplast, made contact with the carbon fibre dealer Structil. The objective : to be able to come in possession of the required materials for a 5 meter long element, as soon as possible.

After having analysed the damage, it was obvious that the halyards literally cut the mast, and it seemed more efficient to make a new profile than to rebuild the old one. The city of Le Mans (located west of Britanny), half way between the shipyard and the Structil warehouse, was chosen as a meeting point.
This Monday, around 5 PM (French time/4H00 GMT), the disposition of the first carbon layer had already been accomplished in each half-mould, and the first "cooking" phase could begin at 120°C – with 24 hours of advance on the 2 weeks schedule.

A "7 Phase" repair

As soon as this first cooking operation (organised around teams working on 8 hours watches) is over, the second phase will consist in laying the core of the sandwich – Nomex – before getting back to the oven. After this second cooking stage, the inside skin will be put in place before a third cooking operation. These 3 operations should be over by next Saturday, February 23rd.
The second week will consist in assembling the 2 half-shells of the new mast section (phase 4). Then it will be time to make the junction between the mast's head and the mast itself, by working the carbon sheets in layers (scarf). The paint job and the equipment re-fitting will remain (phase 6), before of course putting the mast back in place (phase 7).

Despite a busy schedule at Multiplast – construction of the Class America for the French entry Areva, and finish of the 60' trimaran Gitana – and thanks to the shipyard's experience, staff and equipment, Orange's mast should be ready by March 2nd or 3rd. This would allow Bruno Peyron to go back after the Jules Verne Trophy before the deadline he had himself set on the 10th of March while preparing his project.

In Geronimo's wake

Launched by the Multiplast yard at the end of July 2001, Olivier de Kersauson's 34m maxi trimaran has, despite a similar mast incident in November 2001, crossed the starting line of the Jules Verne Trophy this morning at 2:25 French time (1:25 Gmt). The imaginary line is set between Ushant Island (France's most western tip) and Cape Lizard (GB). The awaited duel between a catamaran and a trimaran for the fastest sailing journey around the world will eventually take place. The Multiplast team will watch the battle closely, the two boats having left their shipyard, since Orange was designed by the Gilles Ollier Design Team (formerly Innovation Explorer, second in The Race 2000/2001).