50 years of Rondal: The specialist behind the biggest rigs

The story began in 1976, when Wolter Huisman, the former owner of the current brand Royal HuismanWolter spun off the mast building department of his shipyard into a separate company. Wolter founded Marquip, as the company was then called, with a dual focus: mast building and the supply of licensed components. The aim was to control both product quality and delivery. It wasn't long before the company was more than just a production and distribution centre. It became a launch pad for new ideas and set out to become an industry leader in masts, booms, hatches and fittings.

The first hydraulic mast-lifting system, which was installed on the "Flyer II" in 1981, was one of the results of this ingenuity. It was developed according to the specifications of designer Germán Frers and made rigging faster, safer and easier. The mast hoist was just the beginning. At the beginning of the 1980s, the growing number of

The demand for larger, more luxurious yachts and the desire to sail them with fewer crew members triggered a wave of product innovations. Furling masts, developed for the first time for large yachts, and hydraulic furling systems were among the advances.

When Marquip outgrew its premises in 1983, the company moved to a larger facility. The new location made it possible to build larger masts and equip a machine hall with tools such as lathes and milling machines. Wolter, known for his keen eye, made his daily rounds through the hall. He followed every process closely, pausing to ask how a weld was made or why a particular technique had been chosen. Outsourcing would have reduced costs, but Wolter was not prepared to compromise. He kept production in-house and weighed every decision against the same question: Can we do it better?

The revival of a legend

By 1989, the company had evolved beyond its original identity and was renamed Rondal. The name is a nod to the shipyard's birthplace (Ronduite) and to Marquip's pioneering work in the use of aluminium. The focus shifted to the product range, which at that time included hatches, fittings, booms, winches and masts. In the same year, Rondal built a 53-metre mast for the "Endeavour", J-Class and America's Cup challenger - the company's tallest mast to date. No commercially available profile could accommodate this cross-section, and a customised design for a single mast was not profitable. Instead, Wolter Huisman decided to construct the mast from bent aluminium plates. This approach offered clear advantages: Different plate thicknesses made it possible to achieve a smooth, precise taper, reduce the overall weight and lower the centre of gravity of the mast. Dozens of other masts were built using the same technique, including those for "Cyclos III" (Royal Huisman, 42 metres) and "Juliet" (44 metres). The new mast not only brought "Endeavour" back to life and legendary status, but also marked a decisive step towards higher, fully customised rigs.

Much of the progress can be attributed to Wolter's inventiveness, but customers also played a role. The owner of "Juliet" was an early adopter of new technologies. His vision inspired the development of a single-shaft capstan winch. The system ran smoothly, proved to be reliable and required virtually no maintenance, as a previous inspection of the winch on "Juliet" confirmed. After more than thirty years in service, only minor cosmetic work was required. Then there was Jim Clark, the Silicon Valley entrepreneur behind "Hyperion" (RH, 47 m). His concept was bold, forward-looking and unmistakably high-tech.

Only carbon fibre was an option for the mast. Since Clark was adamant and the competition was willing to take a chance, Wolter agreed to build the mast. He was determined to do it better than anyone else, even though he had no experience with composite materials and didn't own a plant big enough for the job.

Carbon comes into play

To meet the challenge, Rondal built a composite furnace that can reach temperatures of up to 100 degrees Celsius and accommodate Panamax-length masts. The Dutch company also invested in new technologies and brought on board top specialists from the composites industry - a clear signal to the industry that Rondal was entering the age of carbon fibre. Working with resin engineers from SP Systems (now Gurit), the team developed a two-component prepreg material and refined a non-autoclave curing process that later became the standard in superyacht construction. The mast was a ground-breaking innovation. At 60 metres, it was the tallest that had been built to date and followed the same principles behind the seamless, one-piece constructions that Rondal still builds today.

In 2010, the team temporarily enlarged the furnace to accommodate the 61 metre high mast for "Athos" (Holland Jachtbouw, 62 metres) - a solution that soon became the standard. The hall was extended again to accommodate the 70 metre high masts for "Sybaris" (Perini Navi, 70 m), "Pink Gin VI" (Baltic, 54 m) and "Ngoni" (RH, 58 m). Targeted investments helped Rondal to maintain its leading position in the construction of single masts. These included an ultrasonic tester for non-destructive testing, seven and nine metre autoclaves and a fibre cutting machine. The investment combined with the team's expertise has resulted in a portfolio that goes far beyond masts. This includes the world's largest carbon rudder for "Sea Eagle" (81 m), the complex keel box for "Nilaya" (RH, 47 m) and the curved superstructure for "Sarissa" (RH, 60 m).

Weight savings that count

In the early 2000s, competitiveness became an increasingly important factor for superyacht owners. Rondal - founded to supply racing yachts - was already well positioned thanks to its long-standing focus on high-performance components. One example of this is the furling boom installed on "Saudade" (RH, 34 metres) in 1994. Its clew pusher connects the clew to the leech system and thus optimises the downhaul tension at full sail area and in all reefing positions. Another example is the "Visione" (Baltic, 45 m), which offers a lighter, yet more stable and rigid construction.

The mast developed for "Ngoni", which is designed for a wide flared fathead mainsail, drove this idea forward. The weight saving on "Nilaya", which was delivered in 2023, went even further. The double-tapered masthead alone saved 50 kilograms compared to a standard taper. The running backstay system made it possible to use lighter stays and components, while more compact winches enabled additional savings. Overall, the "Nilaya" configuration resulted in a weight reduction of 1.2 tonnes compared to more conventional arrangements.

In 2023, Rondal rebuilt its curing oven. With an area of 1,000 square metres, it became the world's largest facility for one-piece carbon masts - a modern upgrade for ever larger projects, including the mast currently under construction for Royal Huisman's 85-metre-long Project 410. Details are still under wraps, but one thing is clear: to cope with the loads, the team had to develop the largest sail system in Rondal's history. Work is also continuing on the captive winches. The latest systems offer easier integration and a good balance between light weight and durability. The team is also realising lightweight reel winches that can handle pulling forces of up to 40 tonnes. Rondal recently installed a new test rig that simulates loads of up to 150 tonnes, underlining the company's commitment to visionary thinking.

The Aero Wing Sail and Hydrogenerator are Rondal's answer to the increasing demand for energy generation and alternative propulsion. The Aero Wing Sail, a free-standing wing made of carbon, attracted attention at the last Monaco Yacht Show, where it was seen on multihull concepts by Royal Huisman and Dixon Yacht Design, for example "Aera" (50 m). The Hydro Generator is an electric pod with propellers that supplies the entire hotel operation of a yacht with electricity while underway. Four units have already been sold, with great interest in the 50- to 60-foot segment.

Beyond the horizon

Rondal assumes that its niche expertise will also find applications outside of yacht building, for example in shipping, the offshore sector and the automotive industry. The anchor winch, which emerged from the captive winches developed for "Juliet", is one such crossover product that is now meeting demand in the motor yacht market. The same applies to the sliding door system, which was originally developed for "Athena" in 2004 and has now been adapted, including trackless configurations. Interest is also growing outside the maritime sector. Recent projects include a crank assembly for a high-tech company, which can achieve an acceleration of 100 g as well as the design and manufacture of carbon components for a Formula 1 racing simulator.

Looking back on these formative years and the journey so far, one thing stands out in particular: Rondal has never shied away from challenges, no matter how big they were. For Managing Director Harald Lubbinge, the way forward is clear: "We must remain innovative and continue to drive new developments by working together with research institutions, customers and suppliers." At Rondal, innovation also means that new and improved components continue to fulfil the company's current promise: maximum reliability. "Our products are installed on yachts that are exposed to all kinds of challenges, from changes of plan to unpredictable sea conditions. They must therefore be designed to withstand the demands and offer uncompromising performance. Full stop."

Interview: "We are picky"

Harald Lubbinge is Managing Director at Rondal. He spoke to BOOTE EXCLUSIV about tapping into new markets and why aluminium is still indispensable.

Rondal has undergone a significant transition from aluminium to predominantly carbon products. Have you had any previous contact with these materials or composites?

I have experience of running technology-led manufacturing businesses - in operations, delivery and building teams. When it comes to composites, Rondal already had world-class specialists. My experience comes into play where consistently successful production of advanced composites is critical: Process control, planning, risk and quality management. Carbon is an incredible material, but only if you can deliver it repeatedly and reliably. This is where leadership and structure are really important.

Which areas or segments of the company did you focus on when you joined Rondal?

Systems thinking. The true value of Rondal lies not only in the components, but in integrated solutions that work together: technology, production and service, customised to the actual requirements of the yacht.

What do you think of the potential of the Aero Wing Sail project?

Great potential, because it represents a real change in the market. Owners want lower emissions and smarter energy utilisation, but they also want solutions that are safe, practical and easy to use. What I like is the maturity of the project: we have finalised the concept phase and received approval in principle from Lloyd's Register. This is a significant step, as it validates the design and safety principles and advances the implementation in practice.

Are you a sailor yourself?

I enjoy travelling in the world of sailing. But most importantly, Rondal works with people who know the reality on board. Our teams include engineers and specialists who know sailing - so we don't design for theory, but for real crews and real conditions.

On the other hand, Rondal is tapping into new markets, for example with winches for large motor yachts. Are there any other sectors that Rondal is focussing on?

Yes, two areas stand out in particular. The first is the motor yacht market: systems that improve comfort, safety and reliability - mooring winches, wind protection devices, entrances, sliding door solutions. Our promise fits perfectly here: "We develop for a reassuring feeling." The second is the crossover innovation. Wind-assisted propulsion is becoming increasingly important beyond the yacht sector, and our expertise in composite technology can also be easily transferred to specialised, high-tech individual applications. We are selective, but the opportunities are real.

The links between Rondal and Royal Huisman are obvious. What is the current percentage of products manufactured for Royal Huisman?

It depends on the order backlog and we don't usually publish exact percentages. What I can say is that we are currently building four carbon masts, and all four are for Royal Huisman yachts. We are simultaneously involved in yacht projects for international shipyards and also carry out work outside yacht building - so the portfolio is broader than just a single business relationship.

Where can Rondal's roots in aluminium still be felt? For which parts is it indispensable?

Firstly, even though we make some capstan winches from carbon today, many aluminium winches and hardware applications make sense, especially when it comes to balancing strength, machinability, durability and ease of maintenance. Secondly, aluminium remains crucial in the refit and replacement sector. A good example of this is our replacement rigs - such as the one for a 50 metre ketch, for which we manufactured, successfully shipped and erected a 49 metre main mast and a 36 metre mizzen mast with furling system. Ultimately, regardless of whether we opt for aluminium or carbon, the goal is always the same: a long service life and maximum reliability.