Sailboat mast

carbonstainless steelaluminum

Overview
CUL-Masten designs and manufactures laminated carbon masts for yachts and sailboats, serving recreational sailors and competitive regatta crews. Masts are engineered and produced in Germany with attention to weight distribution, longitudinal stiffness and load transmission. Most fittings and sleeves are available in carbon or stainless steel according to application.

Laminate structure
Production allows tailor-made laminate schedules. Fiber orientation is adapted to the mast profile and load cases; different fiber types can be combined. We use aviation-grade epoxy resin with a GL-certified hardener (temperature resistance > 100°C). Wall thickness is tapered from base to top and reinforcement is concentrated up to the main boom to manage peak loads, resulting in a lower center of gravity and improved sailing performance.

Mast groove, rail, slider...
The mast groove is molded integrally into the profile to save weight and increase longitudinal strength, creating a V-shaped internal base acting as a reinforced beam.

• directly incorporated into the carbon profile
• up to 20% higher longitudinal strength vs. external rail
• lower weight compared with external rail systems
• mainsail system exchangeable at any time
• one system — multiple options

Mast base

• multiple base variants available
• materials: carbon, stainless steel or aluminum
• deck- or keel-mounted options
• attachment for halyard swivels and deck feed-throughs
• hydraulic solutions possible
• customized according to customer requirements

Downhaul fitting

• full-carbon sleeve
• bonded over full surface for optimal load transfer
• reinforced bolt area to prevent deformation
• stainless steel bolt and receptacle

Boom fitting

• full-carbon sleeve
• flange-bonded for best force transmission
• reinforced bolt area to prevent deflection
• stainless steel bolt with shackle for mainsail throat and reefing eyes
• optional hook or snapper available
• custom adjustment possible

Halyard exits

• fully flanged to prevent friction between halyards and carbon fiber
• stainless steel sleeves where specified

Spinnaker pole fitting

• high-strength stainless steel
• profile-adapted design
• optionally with rail for lateral adjustment

Spreaders fitting

• full-carbon reinforcement
• fully bonded for load transmission
• spreaders removable for storage (e.g. winter)
• stainless steel spreader receptacle
• reinforced for terminal shroud attachment

Spreaders

• carbon spreaders from aerodynamically shaped profiles
• available in sizes matched to mast profile and application
• easy to remove
• secure and tight fit
• material thickness and fiber angle adapted to load

Forestay reinforcement

• full-carbon reinforcement for shrouds, roller boxes and forestay fitting
• shroud suspension and backstays via terminals or bolts
• jib halyard guide for furling systems available
• separate roller box for winding units possible

Forestay fitting

• optimized load introduction
• available with up to 3 drop discs
• roller box removable for maintenance
• combinable with jumper or diamond stays depending on rigging

Roller boxes

• made of carbon or stainless steel
• 1, 2 or 3 drop configurations
• smooth-running, durable drop discs
• easy dismantling for maintenance

Tapered top

• top tapering available on request
• reduced aerodynamic drag
• appealing design
• reduced weight aloft

Top fitting

• completely made of carbon fiber
• easy to dismantle via special fastenings
• simple maintenance of halyards and sheaves
• various configurations per customer requirements
• halyard arrangements for mainsail and optional code sails
• option for reduction gearing for halyards
• optional bracket for instruments and masthead light
• optimized load transmission and wide backstay lead
• attachment for backstay whip or double back-to-back arrangement possible

Profile sizes (table)
Profile size | Dimensions | Weight | Ixx | Iyy
104er Profile | 104 x 67 mm | 1,0 kg/m | 39 cm⁴ | 85 cm⁴
105er Profile | 106 x 67 mm | 1,2 kg/m | 40 cm⁴ | 100 cm⁴
106er Profile | 106 x 69 mm | 1,4 kg/m | 57 cm⁴ | 117 cm⁴
110er Profile | 110 x 70 mm | 1,1 kg/m | 47 cm⁴ | 104 cm⁴
111er Profile | 112 x 71 mm | 1,4 kg/m | 58 cm⁴ | 131 cm⁴
112er Profile | 112 x 72 mm | 1,5 kg/m | 68 cm⁴ | 141 cm⁴
117er Profile | 117 x 78 mm | 1,2 kg/m | 62 cm⁴ | 132 cm⁴
118er Profile | 118 x 79 mm | 1,5 kg/m | 76 cm⁴ | 157 cm⁴
120er Profile | 120 x 79 mm | 1,7 kg/m | 78 cm⁴ | 191 cm⁴
140er Profile | 140 x 88 mm | 1,7 kg/m | 130 cm⁴ | 312 cm⁴
141er Profile | 142 x 88 mm | 2,0 kg/m | 132 cm⁴ | 366 cm⁴
142er Profile | 142 x 90 mm | 2,4 kg/m | 176 cm⁴ | 426 cm⁴
168er Profile | 168 x 108 mm | 2,1 kg/m | 226 cm⁴ | 603 cm⁴
170er Profile | 170 x 109 mm | 2,5 kg/m | 266 cm⁴ | 738 cm⁴
172er Profile | 172 x 111 mm | 3,1 kg/m | 348 cm⁴ | 895 cm⁴
197er Profile | 197 x 110 mm | 3,0 kg/m | 370 cm⁴ | 1069 cm⁴
199er Profile | 199 x 110 mm | 3,2 kg/m | 375 cm⁴ | 1220 cm⁴
200er Profile | 200 x 112 mm | 3,7 kg/m | 475 cm⁴ | 1429 cm⁴
218er Profile | 218 x 113 mm | 3,3 kg/m | 421 cm⁴ | 1354 cm⁴
220er Profile | 220 x 115 mm | 4,1 kg/m | 536 cm⁴ | 1684 cm⁴
222er Profile | 222 x 115 mm | 4,4 kg/m | 550 cm⁴ | 1944 cm⁴

Technical specifications

• Product: Carbon mast (designed and manufactured in Germany by CUL-Masten)
• Material: carbon fiber laminate with aviation-grade epoxy and GL-certified hardener (temperature resistance > 100°C)
• Custom laminate design and fiber orientation adapted to mast profile; option to combine fiber types
• Integrated mast groove molded into the profile for weight saving and increased longitudinal strength
• Reinforcements from base to main boom; tapered wall thickness to lower center of gravity
• Mast base options: carbon, stainless steel or aluminum; deck- or keel-mounted; hydraulic and bespoke fastening solutions
• Fittings: full-carbon sleeves for downhaul and boom fittings; stainless steel bolts and receptacles where specified
• Options for roller boxes (carbon or stainless), forestay fittings (up to 3 drop discs) and removable spreaders
• Profile sizes available for vessels up to approx. 45 feet (see profile table)
• Top fitting variations including halyard arrangements and optional instrument/light bracket