In the May issue, one SAIL reader raised questions about the production methods used by Bavaria Yachts. Due to limitations in space, only an edited version of Bavaria’s reply ran on the Feedback page. Here is the unabridged response.

Efficiency vs. Safety

Re: “The World’s Most Efficient Boat Builder” (February). You do a disservice to your readers by heralding Bavaria’s efficiency without mentioning the possible tradeoffs. In April of 2005, one sailor died when a Bavaria Match 42 lost its keel in Croatia. The subsequent investigation revealed a much broader problem, and Bavaria ultimately was forced to recall all 150 of the 38- and 42-foot Match models it has produced. It seems the company failed to install the necessary backing plates. Perhaps 10 days from start to finish is just too fast to build a qualified yacht.
Lawrence Sterne
Greenwich, Connecticut

Bavaria’s Unabridged Response

I have read the response of Mr. Lawrence Sterne to your article on the Bavaria Yachts manufacturing facility. All of us associated with Bavaria are deeply saddened by the loss of life associated with the tragic accident that occurred in Croatia this past summer, the official investigation of which is still ongoing.

The fact that Bavaria issued a retro fit order on the 38 and 42 Match series boats is accurate, unfortunately the time line is not. The factory, on July 13, 2004, well prior to this incident, informed all dealers that a retrofit of a larger stainless steel backing plate to better distribute the keel loads was being mandated and they supplied the necessary parts to accomplish this. With this installed, both Bavaria 38 Match and 42 Match series boats have competed successfully in major ocean races world-wide and in so doing encountered conditions that led to the withdrawal of many of the entries.

The construction of the Bavaria 42 Match was verified immediately by the designer and by the responsible body for the certification after the tragic accident and was confirmed to be within the CE-regulations and safety requirements. The actual cause of the accident has not been finally determined. What is known is that other boats in this fleet have serious damage to their keel bottoms, confirming groundings and causing structural damage as a result. The owner of this racing fleet and the skipper of the capsized yacht have subsequently been fined in Croatia after an official investigation by the local authorities. This action was taken due to the fact the race was not registered and officially authorized, and the race boats had not been inspected and permitted for Croatian waters, as required for official registration.

Subsequent to the accident, Bavaria did an extensive review of all their design parameters and construction methods and determined that while further reinforcement of the keel area of the 42 Match and 38 Match may be advisable, none of the Cruiser series boats or the 35 Match required any such modifications. The upgrade of all Bavaria 38 Match and Bavaria 42 Match yachts was a preventive action to increase the safety and stability of those boats. In the aftermath of this accident, if anybody is sensitive to ensuring the structural integrity of the boats they build it must be Bavaria.

I would believe that Mr. Sterne is relying, like many of us, on the photos and opinions that appeared in the weeks following the accident, and very little of substance can be determined from what has appeared. One thing that is evident from the photos that have been published is that the mandated retrofit of the larger backing plates was not completed on the vessels that are the subject of these photos.

The manufacturing time savings referred to in your article are achieved in all areas of manufacture from procurement to woodworking, from component assembly to waste disposal. It is not concentrated in lamination, which enjoys savings of its own based on supply techniques as well as controlled environmental curing of the hulls and decks, similar technology to that used in the manufacture of the laminated components of many of the latest generation of military aircraft.

As to the unsubstantiated assertion that Bavaria “has a history of life-threatening manufacturing defects” I would doubt that Bavaria would be enjoying the world-wide growth that it is if this were in anyways the case.

Any product failure regardless of the reasons is regrettable, when it is associated with injury or loss of life it is just that much more distressing to all involved. This was a tragic incident, one that once it is fully investigated will supply accurate answers for us all.