Composite Masts, Booms & Spars for Sailing, Power and Commercial Vessels

[This article has been updated 16 Sept 2026] A composite mast can be a highly engineered carbon structure for a performance yacht, or a practical solution to a weight, corrosion or operating problem aboard a commercial vessel.

Triac Composites builds both.

From our manufacturing facility in Vietnam, we produce masts, booms, bowsprits and related composite structures for sailing, power and commercial vessels. Our processes include prepreg carbon and autoclave curing, vacuum infusion, composite tooling and 7-axis robotic machining.

Two recent projects illustrate the range: a large spreaderless carbon mast for the Rapido 40 Racer, and a 76 kg composite mast built to replace a 700 kg steel structure aboard an 85-metre passenger vessel.

A large, autoclave-cured carbon mast

The Rapido 50 sailing trimaran mast is a substantial prepreg-carbon structure engineered by Morrelli & Melvin.

It is spreaderless and tapers in both fore-and-aft and transverse directions. Producing that geometry while meeting the specified laminate and finished-weight requirements places demands on tooling, material control and manufacturing accuracy.

The mast is manufactured at Triac from prepreg carbon and autoclave cured. Triac's 7-axis KUKA robotic system is used for precision machining where required.

The size of a composite structure changes the manufacturing challenge. A technician at the masthead for a Rapido 50 sailing trimaran provides some perspective on the scale.

The Rapido project is useful to Triac for reasons beyond building a sailing mast. It demonstrates our ability to work with sophisticated engineering developed externally, translate it into a manufacturing process, and produce the finished structure in Vietnam.

A very different mast — and a different solution

An 85-metre passenger vessel operating in Vietnam and Cambodia presented a completely different requirement.

Its existing steel mast weighed approximately 700 kg and needed to be lowered regularly so the vessel could pass beneath bridges. The weight placed significant loads on the lifting mechanism and supporting structure, and crew had to assist with the operation.

Carbon fibre was not required.

The replacement was manufactured using E-glass reinforcement over a structural PVC foam core and vacuum infusion. The finished mast weighed 76 kg — approximately 89% less than the steel structure it replaced.

This composite mast on an 85m commercial vessel weighed just 76kgs - 624kgs less than teh original steel mast.

Reducing the weight also allowed the vessel's hydraulic lifting system to be replaced with a compact electric actuator.

For the operator, the important result wasn't the composite technology itself. It was a mast that solved the operational problem.

Read the full 700 kg to 76 kg commercial mast case study

Manufacturing to the requirement

These two masts use different materials and different manufacturing processes because they have very different jobs to do.

That is an important distinction.

Triac is not tied to a single composite process. Depending on the customer's engineering, specification, quantities and commercial requirements, production can involve prepreg and autoclave curing, vacuum infusion, robotic machining, CNC machining and purpose-built composite tooling.

For outsourced composite work, however, equipment is only part of the equation.

The drawings and laminate specifications have to be understood. Tooling has to be accurate. Materials and processes have to be controlled. Finished components have to meet the agreed requirements. And the customer needs confidence that what has been agreed will actually be produced.

That is the manufacturing relationship Triac is set up to provide.

Built in Vietnam for international customers

Triac operates from a dedicated composite manufacturing facility in Ho Chi Minh City, Vietnam.

Locating production in Vietnam provides a competitive manufacturing base, but cost only matters if the finished product meets the required standard.

Our marine work ranges from individual high-value structures to repeat production, working with international designers, boatbuilders and shipyards. Rapido Trimarans is one example; commercial marine projects provide others.

The objective is straightforward: agree what is to be manufactured, establish the required standard and production process, and deliver accordingly.

See the manufacturing behind the finished product

Barefoot Doctors Sailing visited the Triac factory while when Rapido's forst 40' Racer was in production.

Their video includes coverage of the Racer's spreaderless carbon mast, asymmetric C-foils and other composite structures under manufacture, providing a useful look at the processes behind the finished components.

The carbon C foils for the Rapido 40 Racer; built by Triac Composites. Click to play the video.

The video is focused on a sailing project, but the manufacturing capability behind it is available to other marine customers.

More than masts

The same facility produces carbon booms, bowsprits, beams, foils, rudders, daggerboards, structural components, tooling and other custom composite assemblies.

For a boatbuilder, shipyard, naval architect or equipment manufacturer, the starting point does not need to be an existing Triac product.

It can simply be a component or structure you need manufactured.

Talk to us about your next project

If you are looking to outsource a composite mast, spar or other technically demanding composite structure, send us the drawings, specifications or an outline of the requirement.

We can then determine whether the project is a good fit for Triac's manufacturing capabilities and discuss process, quantities, commercial requirements and delivery.

Enquiries

Email info@triaccomposites or Phil Johns at phil@triaccomposites.com