78' Commercial Dive Vessel
Hurricane Hull Repair
Emergency structural repair after hurricane strike — marine-grade aluminum welding, back in service in 4 weeks
Project Overview
A 78-foot commercial dive vessel suffered significant hull damage when a floating dock broke free during a Category 2 storm and struck the vessel repeatedly at the waterline. The operator needed the boat back in commercial service — revenue stopped the day the boat was damaged. DolFab performed a full structural damage assessment, sourced and fitted new 5083 marine aluminum plate sections, and returned the vessel to certified working condition in four weeks.
The Challenge
Hurricane damage is never just what you can see. The visible impact zones at the waterline masked hidden deformation further into the hull structure — frames, longitudinals, and a section of keel plate were bent or cracked under loads the hull was never designed to sustain. Cutting out damage without proper assessment risks removing structural material that was still load-bearing. Speed was critical: every week out of service was lost charter revenue.
The Solution
DolFab's structural team performed a full methodical damage survey before a single cut was made — probing each frame and longitudinal for deformation, marking the actual extent of structural compromise. Damaged panels were excised cleanly to sound material. Replacement sections were cut from 5083-H116 marine plate (saltwater-rated), prepped with a double-bevel groove for full-penetration welds, and welded by a certified marine welder. Internal frame repairs were completed simultaneously. Vessel passed coast guard inspection and returned to dive charter operations on schedule.
Damage Scope & Repair Summary
Project Timeline
Full hull survey from interior and exterior. All deformed framing and plating marked. Extent of structural compromise mapped before any cutting began.
Damaged hull sections cut to sound metal. Internal frame sections removed. 5083-H116 marine plate sourced and CNC-cut to exact replacement dimensions.
Frame repairs and replacements completed first. New hull panels back-gouged and welded with full-penetration seams. All welds visually inspected and dye-penetrant tested.
Coast Guard inspection of all structural repairs. All panels ground flush and primed for antifouling. Vessel splashed, sea-trialed, and returned to commercial dive charter operations.
Services Performed
Project Details
- Vessel
- 78' Commercial Dive Charter
- Repair Type
- Hurricane Hull Damage — Emergency
- Material
- 5083-H116 Marine Aluminum
- Weld Type
- Full-Penetration MIG/TIG
- Panels Replaced
- 6 Hull Sections
- Timeline
- 28 Days — Back in Service
- Inspection
- USCG Certified — First Inspection
- Location
- Fort Lauderdale, FL
"After the hurricane we thought we were looking at months out of service. DolFab had us back diving in four weeks. The structural assessment alone saved us from cutting out material we didn't need to — they know aluminum work better than anyone on the water down here."
Vessel Damage? We Move Fast.
Storm damage, collision repair, structural failures — we assess first, cut second. ABS and USCG certification available. Most emergency hull jobs complete in 3–5 weeks.