REFIT

Rigging service program

BSI Recommended Standing Rigging Maintenance and Service Guidelines

BSI has developed a Rigging Service Program that stress preventive maintenance to protect the structural integrity of a yacht’s rigging, enhances performance, longevity and safety of the yachts guests and crew while maximizing the investment with limited service down-time. Yachts participating in the Rigging Service Program will have their maintenance records continually updated with the assurance this information is safely secured at BSI Headquarters in Denmark. (BSI Service Log)

No yacht is alike

BSI professionals, with years of rigging experience, know that all vessels are not built or treated equally. 

Furthermore, our vast database of delivered and serviced rigging equipment gives us a continually improving understanding of wear & tear over a yachts life from the club racer to the largest blue water cruising yachts. No yacht is alike so BSI therefore offers flexibility in the program to coincide with the yachts scheduled refit plans. Pre-Service inspections are recommended as this allows both BSI and the yacht to plan in advance and minimize down time.

Factors effecting life expectancy

The life expectancy of a set of rigging, whether rod, fiber or wire, can be affected by many factors:

  • Age of rigging
  • Miles sailed
  • Sailing conditions
  • Designed safety factors
  • Proper tune
  • Adherence to maintenance schedules
  • Traumatic events such as groundings, knock-downs and flying jibes
  • Environmental conditions and Corrosion 

Customized service

For yachts using composite rigging, either exclusively or in combination with some stays in rod, the service recommendations remain the same for the metal hardware used as attachments of composite stays. 

BSI work with professionals, individual owners, captains and management companies to establish a customized service schedule tailored to the yacht’s specific needs. Service recommendations are based on rigging manufacturer’s specifications, the vessel’s history of sailing and maintenance, future sailing plans, and the yacht’s projected down time and budget. Therefore, BSI have developed a series of Categories to help identify which classification the yacht falls into. These categories will tend to experience different mileage and sailing conditions. 

Find the best service program for you

Please type in miles or years at sailing.

BSI Rigging Service # 1 recommended before the end of Year Five of sailing, or 50,000 to 60,000 miles. The partial refit services include:

  • Un-stepping the rig and removing all rigging components
  • Cleaning and inspecting all fittings, rigging and rod heads
  • Non-destructive testing—(NDT) with dye penetrant, where determined necessary
  • Re-heading and re-seating all Diagonals, Forward and Aft Rods, if deemed necessary
  • Re-furbishing and polishing of all fittings in accordance with manufacturers guidelines 
  • Reviewing history of non-metallic rigging, bench testing or replacement according to manufacturer’s recommendations. Generally, Kevlar Stays are replaced at this time 
  • Full lubrication and dressing
  • Re-stepping
  • Dock tuning and sea trial
  • Forward inspection notes to BSI for update of BSI Service Log

BSI Rigging Service # 2, recommended at 9 years of sailing or 90-100000 miles The full refit services include:

  • Un-stepping the rig and removing all rigging components
  • Cleaning and inspecting all fittings, rigging and rod 
  • Non-destructive testing—(NDT) with dye penetrant, where determined necessary
  • Re-heading or replacement of all vertical rods
  • Re-heading and re-seating all Diagonals, Forward and Aft Rods
  • Re-furbishing and polishing of all fittings of all fittings in accordance with manufacturers guidelines
  • Reviewing history of non-metallic rigging, bench testing or replacement according to manufacturer’s recommendations. Generally, Kevlar Stays are replaced at this time
  • Full lubrication and dressing
  • Re-stepping
  • Dock tuning and sea trial
  • Forward inspection notes to BSI for update of BSI Service Log

BSI Rigging Service # 3, recommended at 13 years of sailing or 120-130000 miles The partial refit services include:

  • Un-stepping the rig and removing all rigging components
  • Cleaning and inspecting all fittings, rigging and rod 
  • Non-destructive testing—(NDT) with dye penetrant, where determined necessary
  • Replacement of any rod(s) from original manufacture
  • Re-heading and re-seating all Diagonals, Forward and Aft Rods
  • Re-furbishing and polishing of all fittings of all fittings in accordance with manufacturers guidelines
  • Reviewing history of non-metallic rigging, bench testing or replacement according to manufacturer’s recommendations. Generally, Kevlar Stays are replaced at this time
  • Full lubrication and dressing
  • Re-stepping
  • Dock tuning and sea trial
  • Forward inspection notes to BSI for update of BSI Service Log

BSI Rigging Service # 4, recommended at 17 years of sailing or 160-180000 miles At this time any of the remaining material from the original delivery is coming to the end of its expected service life and should probably be replaced. Consideration should also be given that at the next refit, BSI Rigging Service #5, will be when the yacht, and any originally supplied rigging material, will be over 20 years old.  The complete service history should be reviewed along with future sailing plans and BSI will issue a recommendation but generally we recommend a full service along the lines of Rigging Service #2, but adjusted for replacement of original material as necessary. The full refit services include:

  • Un-stepping the rig and removing all rigging components
  • Cleaning and inspecting all fittings, rigging and rod 
  • Non-destructive testing—(NDT) with dye penetrant, where determined necessary
  • Re-heading or replacement of all vertical rods
  • Re-heading and re-seating all Diagonals, Forward and Aft Rods
  • Re-furbishing and polishing of all fittings of all fittings in accordance with manufacturers guidelines
  • Reviewing history of non-metallic rigging, bench testing or replacement according to manufacturer’s                                         recommendations. Generally, Kevlar Stays are replaced at this time
  • Full lubrication and dressing
  • Re-stepping
  • Dock tuning and sea trial
  • Forward inspection notes to BSI for update of BSI Service Log

BSI Rigging Service # 5, recommended at 21 years of sailing or 200-220000 miles At this time any of the remaining material from the original delivery should be replaced and if the yacht has followed the recommended service schedule above it is now time for another partial refit.  The partial refit services include:

  • Un-stepping the rig and removing all rigging components
  • Cleaning and inspecting all fittings, rigging and rod 
  • Non-destructive testing—(NDT) with dye penetrant, where determined necessary
  • Replacement of any rod(s) and fittings from original delivery
  • Re-heading and re-seating all Diagonals, Forward and Aft Rods
  • Re-furbishing and polishing of all fittings of all fittings in accordance with manufacturers guidelines
  • Reviewing history of non-metallic rigging, bench testing or replacement according to manufacturer’s recommendations. Generally, Kevlar Stays are replaced at this time
  • Full lubrication and dressing
  • Re-stepping
  • Dock tuning and sea trial
  • Forward inspection notes to BSI for update of BSI Service Log

Initial Stepping of Rig(s) Riggers, Spar manufacturers and boatyards use various procedures, but BSI recommend that a complete specification is issued for the vessel at time of installation. Mast Jack loads, Stay Tensions, Turnbuckle settings etc. should be recorded and Mast(s) tuned to manufacturers’ specifications. This information establishes the important baseline that should be kept on file and updated every time work is done to the Rig System, in the yachts BSI Service Log. 

New Yacht – Six Month Inspection  Optional visual inspection of all Rigging and interfaces. This inspection is typically carried out four to six months after delivery. In cases where the yacht receives a comprehensive Sea Trial and Inspection prior to hand over, this inspection can be deferred to an Annual Service. 

  • Comprehensive Rigging System Inspection 
  • Adjust Mast Tune if Required 
  • Forward inspection notes to BSI for update of BSI Service Log
Routine Inspection by Crew
  • Recommended Rigging System Inspection several times a year and before and after a long or heavy passage 
  • Contact BSI for advice if any concerns arise
Annual Service Recommended every Twelve to Fourteen months. The Rigging is slackened to enable Inspection and Servicing. The mast(s) will remain in the vessel throughout the process, which includes:
  • Comprehensive Visual Inspection of the Sail & Rigging System 
  • Complete inspection of all accessible rod heads
  • Re-lubrication of all accessible Rod Heads and Fittings
  • Re-tuning the rig, as necessary
  • Forward inspection notes to BSI for update of BSI Service Log
Pre-inspections, to be carried out prior to each rigging service #1-4.  BSI recommend a pre-service inspection to record all rigging lengths, turnbuckle settings, plus any adjustments or modifications. This allows for a full technical review and a Bill of Materials to be generated in advance reducing the down time and cost to the vessel. If the rigging was not manufactured by BSI a preservice inspection is required to enable a comprehensive technical review to be completed. All fittings and pin sizes, lengths, angles are recorded with the rig under load. A refit estimate and recommendations can be generated, and service schedules reviewed to minimize the downtime of the vessel.

Non-Destructive Testing. Whilst NDT is an important part of the preventive maintenance of yacht rigging it is important to remember that the result, regardless of testing process, will only tell you the condition of the material or fitting at time of testing. It will not give you any indication of how much longer one can expect the material to remain in a satisfying and reliable condition. Once a crack develops in a coldhead it can lead to catastrophic failure within a few months depending on load cycling and we have taken this into consideration when setting the recommended service and re-heading schedules.

Yachts in category 3 and 4 generally have very different service requirements due to the substantially fewer miles they sail each season. The rigging service of these yachts are normally handled by BSI’s Certified Service Centers without direct input from BSI but can in some situations also have owners, and non-professional crew, take care of the maintenance.  The general recommendations that are based upon annual inspections and maintenance with partial or full refits remain the same but the schedule between the various services can be extended depending on the results from annual inspections. 

Annual Service Recommended every Twelve to Fourteen months. The Rigging is slackened to enable Inspection and Servicing. The mast(s) will remain in the vessel throughout the process, which includes:

  • Comprehensive Visual Inspection of the Sail & Rigging System 
  • Complete inspection of all accessible rod heads
  • Re-lubrication of all accessible Rod Heads and Fittings
  • Re-tuning the rig, as necessary
  • Updating BSI Service Log for the yacht

Rigging Service # 1 is recommended from year 5 after launch up to year 8 depending of miles sailed and results from the annual inspections.  The partial refit services include:

  • Un-stepping the rig and removing all rigging components
  • Cleaning and inspecting all fittings, rigging and rod heads
  • Non-destructive testing—(NDT) with dye penetrant, where determined necessary
  • Re-heading and re-seating all Diagonals, Forward and Aft Rods, if deemed necessary
  • Re-furbishing and polishing of all fittings in accordance with manufacturers guidelines 
  • Reviewing history of non-metallic rigging, bench testing or replacement according to manufacturer’s recommendations. Generally, Kevlar Stays are replaced at this time 
  • Full lubrication and dressing
  • Re-stepping
  • Dock tuning and sea trial
  • Updating the BSI Service Log

BSI Rigging Service # 2 is depending on when Rigging Service #1 was done so anytime from 5-8 years from Rigging Service #1, or 10-16 years from initial launch. The full refit services include:

  • Un-stepping the rig and removing all rigging components
  • Cleaning and inspecting all fittings, rigging and rod 
  • Non-destructive testing—(NDT) with dye penetrant, where determined necessary
  • Re-heading or replacement of all vertical rods
  • Re-heading and re-seating all Diagonals, Forward and Aft Rods
  • Re-furbishing and polishing of all fittings of all fittings in accordance with manufacturers guidelines
  • Reviewing history of non-metallic rigging, bench testing or replacement according to manufacturer’s recommendations. Generally, Kevlar Stays are replaced at this time
  • Full lubrication and dressing
  • Re-stepping
  • Dock tuning and sea trial
  • Updating the BSI Service Log

Go to certified service centers