85m Luxury Yacht — Custom A0 Fire Door Package with Designer Finish

Project Overview

A UAE-based yacht builder required 22 custom A0 fire-rated steel doors for an 85m luxury motor yacht. Unlike standard marine doors, yacht doors require a premium finish: flush-mounted handles, concealed hinges, and paint-ready surfaces for the interior design team to apply bespoke finishes. The yacht was classified with Bureau Veritas (BV).

The Challenge

Yacht fire doors must meet the same SOLAS Ch. II-2 fire integrity standards as commercial vessels, but with an aesthetic quality approaching architectural doors. The yacht builder specified: no visible welds on the show side, handle hardware compatible with Italian designer fittings, and surface flatness within 0.5mm/m for lacquer finishing. Standard marine door factories typically cannot achieve this level of finish.

Our Solution

We identified a specialist factory that produces both marine-certified and architectural-grade doors. Their welding process uses TIG (GTAW) on the show face, with all structural welds hidden on the reverse. Each door was laser-measured for flatness before shipping.

Results

• All 22 doors accepted by the interior design team without rework
• BV certification passed on first inspection
• Surface flatness: 0.3mm/m average (exceeded 0.5mm spec)
• Packaging: custom wooden crates with foam lining for air freight to Greece