Hall Spars and Rigging

Products

• Hall Spars & Rigging manufactures several proprietary products
  • SCR Carbon Fiber Rigging, the lowest-windage standing rigging available
  • QuikTrip and QuikConnect lightweight spinnaker pole end fittings
  • QuikVang solid vang
  • Autolock halyard lock, the automatic halyard lock with no trip line
  • Oceanfurl furling boom, the carbon-fiber furling boom for big boats
  • VBoom carbon-fiber boom that captures the mainsail with the assistance of lazy jacks.
  • Simple and elegant Carbon Radar Bracket; lightweight and dampened for smooth operation
• Hall Spars & Rigging in the U.S. serves as a major distributor for leading-edge hardware, such as Harken, Lewmar, Schaefer, Ronstan, Navtec, and every major brand of yachting rope. We are the U.S. importer of Gottifredi Maffioli rope from Italy.

Production Method

• Every Hall carbon-fiber spar is autoclave cured. Our aerospace-quality autoclaves cure at 6 bar (85-100 psi) and a temperature of 120°C (250°F). Hall's high-pressure process eliminates voids and maximizes fiber straightness.
• The U.S. factory has two autoclaves: the 46-meter autoclave cures America's Cup masts and most superyacht spars in one cure cycle. The 20-meter autoclave is used for poles and parts. The European facility has a 45-meter autoclave. The autoclave in New Zealand measures 42 meters. The autoclaves were purpose-built for Hall to our specifications.
• Hall composite structures are seamless and are made on a male mold. Pre-preg unidirectional carbon fiber is laid up around an aluminum mandrel and then autoclave cured. (The mandrel is removed upon curing.) The result is a seamless tube with fibers stretched straight during the heat cycle by the expanding aluminum mandrel. These fibers continue "uninterrupted" around the circumference of the tube, creating the seamless structure.
• Hall leads the industry in autoclave-cured carbon fiber spar production, curing a greater tonnage of carbon per year than any of our competitors.
• Hall carbon spars are built for production yachts worldwide, including models by Wally, Swan, Oyster, J/Boats, Sabre, Farr, Morris, Grand Soleil, Baltic, Shipman, Luca Brenta, and Beneteau. Hall builds custom carbon spars for boats over 35 feet, from grand-prix racers to Volvo and America's Cup boats. We also produce elegant and stylish spars for high-performance cruising yachts and superyachts.
• Aluminum masts are produced for OEM customers only.
• All engineering is completed in-house. Hall engineers use dynamic finite element analysis (FEA) in combination with solid modeling to analyze rig loads and create the lightest, strongest rigs possible. There is a team of engineers on site in each factory.

Factories

• Hall Spars & Rigging operates three complete manufacturing facilities. The U.S. factory is located in Bristol, R.I., our European facility is located in Breskens, Holland, and the New Zealand factory is located in Auckland. All companies operate under the name Hall Spars & Rigging.
• Hall operates a Sales & Service office in the Mediterranean. The office is located in Civitanova, Italy.
• The U.S. facility employs 85 people and occupies 7158 m² production space.
• The facility in Europe has production space of 7600 m² and also employs 90 workers.
• The New Zealand operation began carbon production in July, 2008. There are 30 employees in New Zealand.
• Hall Spars & Rigging manufactures seamless, high-performance carbon-fiber spars for custom and production boats.
• Hall Spars & Rigging assembles standing and running rigging packages for our mast projects as well as for a wide range of customers worldwide. The rigging shops custom fit our SCR standing rigging and regularly retrofit using composite fibers. In addition, there are complete rod heading and cable swaging capabilities.
• Hall operates a virtual storefront for rigging and hardware at www.hallspars.com.