Archives: Projects

Since Hythe Engineering joined forces to collaborate with Whitmarsh Ribs, the workshop has been buzzing with new projects and new trainees that are learning from the decades of experience held by the existing team.  

We recently had the pleasure of sitting down with Haydon Bunter, an ambitious trainee at Hythe. With a passion for learning and an unwavering dedication to his craft, Haydon has quickly made his mark in the industry. In this interview, Haydon shares his insights, experiences, and aspirations as he navigates the exciting world of boat building. 

What do you like most about being a trainee? 

As a trainee, the aspect I enjoy the most is the constant opportunity to learn something new and push myself beyond my limits. Every day brings a fresh challenge, which enables me to step out of my comfort zone.  

What are the best projects you’ve worked on so far? 

One of the most satisfying projects I’ve worked on involved crafting bulkheads and ensuring they fit seamlessly into the boat’s structure. Recently, I had the privilege of completing the SOLAS (Safety of Lives at Sea) project, and worked on both a 625 and a 115 model. However, I’m eagerly looking forward to the RS7 build, which presents a unique construction process and an exciting combination of moulds. 

What skills have you learned during your training? 

Throughout my training, I’ve acquired a diverse range of skills. I’ve assisted with tube removal, joined decks and hulls, flipped decks, placed deck components on dollies, and fitted decks meticulously. Additionally, I’ve been involved in tasks such as electrical cable containment, polishing, finishing, installing limber holes, providing sea trial assistance, weighting boats, fitting tube liners, and executing gel washing.  

I have also learnt the importance of attention to detail and that emphasising quality craftsmanship and finishing is of the utmost importance. When working for high-end clients like we have nothing but the best will do, has taught me to have uncompromisingly high standards. 

What does a typical day look like for you? 

In this line of work, no two days are ever the same. The incredible variety of tasks ensures you never get bored. While it all falls within the realm of boat building, each project is unique, and the methods employed are rarely identical. This ever-changing nature of the job keeps me engaged and motivated. 

What is the toughest thing you’ve had to do or learn? 

One of the most challenging skills I’ve encountered is gel washing. It requires immense precision to consistently achieve the desired results. The standards for gel washing are exceptionally high, and I’m committed to upholding them. Although the technique itself isn’t difficult, the attention to detail required to achieve perfection can be quite demanding. 

What do you envision for your future career? 

I genuinely hope to remain in this industry until I retire. The boat-building industry is incredible, offering fantastic opportunities not only within the UK but also abroad. While I do aspire to start my own business eventually, my current goal is to establish a long-term career with Hythe as there is so much to learn here and I really enjoy being a part of a team with such a wealth of knowledge. I’m content where I am, and see myself continuing to contribute to the great work done by the HTS team for the foreseeable future. 

What advice would you give to someone considering becoming a trainee? 

My advice is simple—go for it! Give it a shot. Regardless of the outcome, I can guarantee you’ll have an incredible experience and gain valuable skills along the way. Even if it doesn’t work out, the lessons you learn during your training will undoubtedly prove beneficial in other aspects of life. Seize the opportunity, and who knows what amazing things you’ll accomplish! 

Haydon said his goodbyes and told us, “Right, I’m gonna go build some boats.”  

Discover more about the history of Hythe and Whitmarsh Ribs.  

Hythe Engineering is assisting with the delivery of the Royal Navy Power Improvement Programme (PIP). The PIP project team draws on expertise from all Hythe divisions, showcasing the company’s impressive capabilities. Part of that team is fourth-year apprentice, Billy Bramble.

 

Hands-On Experience on Prestigious Royal Navy Job

Billy, a plater apprentice at Hythe Engineering, is gaining invaluable hands-on experience working on the high-profile Royal Navy project. Now in the final year of his apprenticeship, Billy is deployed on-site as part of Hythe’s 30-strong team carrying out installation and construction work onboard a naval vessel.

His role enables him to utilise the practical skills he has developed through his 4-year apprenticeship, further enhancing his knowledge and employability.

A Wealth of Future Opportunities

After his apprenticeship, Billy can continue advancing professionally, including potential opportunities overseas. He has his sights set on working abroad or in the oil industry. “The core skillset he’s demonstrating is transferable into most practical industries,” says Matt Cross, Project Manager,

But his hard-working nature didn’t go unnoticed prior to this project. In 2023, Billy and Hythe apprentice Lleyton Hussey received a thank-you recognition award from the team; “They are performing well over and above the standard expected for lads of their experience and maturity.”

 

 

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“Right from day one Billy has shown his eagerness to learn and progress in both practical and academic elements of his apprenticeship. Billy continues to impress me, his operational managers and supervisors with his great attitude and superior job knowledge.

It has been a pleasure to witness Billy grow within the company, going from a quiet first-year apprentice to running his own team afloat. Billy, along with the rest of the 2019 apprentice cohort, are perfect examples of why the apprenticeship program is so important to Hythe Engineering.”

– Alister O’Neill, Training & Security Manager, Hythe Engineering Ltd.

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Hythe Apprenticeships: A Solid Foundation for A Life-Long Career

Choosing the apprenticeship route over university or college has provided Billy with a solid grounding in a well-respected trade, equipping him for a career anywhere in the world.

As well as essential trade skills, Billy has gained many traits employers look for, such as time management, communication, and taking initiative.

The hands-on, practical learning Billy has received puts him strides ahead of a classroom-based education. He has gained real discipline through his commitment to the apprenticeship, and earned credentials recognised nationwide.

 

Investing in Apprentices Secures Hythe’s Future Growth

By investing in motivated young people like Billy through its apprenticeship scheme, Hythe Engineering is securing its future growth, and retaining the skills of our decades-served employees. All while helping young people build their careers in a very well-respected industry.

Offering apprenticeships rather than just academic routes paves the way for more engaged, work-ready employees.

Discover career-starting apprenticeships with Hythe Engineering.

 

Hythe Engineering is utilising its diverse capabilities by assisting with the delivery of the Royal Navy’s Power Improvement Programme (PIP) for the Type 45 Destroyers. This project has enabled Hythe to provide essential support from multiple disciplines and facilities across the company. 

 

The Power Improvement Programme

The PIP is best characterised as a ship conversion project. It will return full confidence in the propulsion systems while also providing a margin of additional electrical power for future upgrades. The PIP affects nearly all marine engineering aspects of the T45, with minor impacts identified ship-wide and on elements of the combat system.

Not helped by COVID, the PIP work on the programme’s first vessel over-ran by a year. But the lessons learned should see subsequent vessels complete their PIP more quickly. 

The PIP is a £160 million contract being delivered by the Ministry of Defence. Hythe Engineering is supporting with the project, currently working on a Royal Navy Type 45 destroyer in the Portsmouth Historic Dockyard.  

Hythe’s Fareham Works is responsible for 80% of the offsite constructive steelwork packages. Its Portsmouth facility has produced over 500 piping spools and penetrations needed for the project. Portsmouth has also completed the remaining constructive items and addressed additional works that have emerged. 

The Hythe Engineering Team 

Hythe has a 30-person strong afloat team on this vessel, installing and advancing the project’s progress. This includes one fourth-year apprentice, plater Billy Bramble. The constructive and pipework teams are led by Aiden Steward and Fred Creamer, respectively.  

According to Project Manager Matt Cross, “Both gents bring tremendous knowledge and experience as well as huge energy and enthusiasm to the project. Having them on the team gives me great confidence that we will deliver successfully.“ 

“I’m looking forward to working with this great team daily, as well as collaborating with other functions like logistics, compliance, and finance,” Cross remarked. “It’s refreshing to work with colleagues who have a real passion for their discipline and take the time to help broaden my knowledge.“ 

Hythe Engineering’s recently revamped business structure promotes smooth communication and information sharing throughout the project lifecycle. It has already proven its worth in enabling a smooth handover from tendering to the project delivery team. Clear and precise details of specifications within the project ensured procurement of the correct materials, with the correct certification requirements. 

Why Hythe Engineering? 

When a deadline’s not just a task, it’s national security. When attention to detail isn’t preferred, it’s critical. When discretion isn’t a request, it’s assumed. 

Our commitment to customers goes beyond the baseline of capabilities as we relentlessly pursue excellence in the face of adversity. We are in our element when engineering precision and innovation meet urgency and where confidentiality is critical.

For engineering information and advice please speak with a member of the team.

2021 and 2022 saw two years of action for the Royal Navy’s Type 23 class.

With such a busy time for NATO and the UK’s defence, it’s imperative that all ships, submarines, and equipment are in good working condition. In January and February of 2023, Hythe Engineering was contracted by BAE Systems to work alongside other industry partners to complete essential maintenance work on the Type 23 vessel to ensure its performance capability was maintained to the highest possible standard of the Royal Navy.

Kent is due to undertake Fleet Operational Sea Training in March 2023, ready for the rigours of front-line deployment. Operational Sea Training involves several weeks of assessment to determine whether a warship is seaworthy and capable of carrying out missions. 

A brief timeline of HMS Kent: 2021 – 2022

In 2021, HMS Kent was one of the escorts for the UK’s flagship aircraft carrier HMS Queen Elizabeth on its maiden deployment to the Pacific Rim last year. The seven-month mission took place across 40 different countries, involving HMS Queen Elizabeth, a task group of eight supporting ships (including HMS Kent), a submarine, five air squadrons and more than 3,700 personnel. 

2022 saw the start of the terrible war, the largest conflict in Europe since the Second World War. Although this obviously dominated the year, for the RN the war has not had huge obviously visible implications but added a greater sense of urgency to the standing patrol tasks and NATO commitments that were already in play. 

Despite their age, the Type 23 frigates (HMS Northumberland, Richmond, Portland and Kent in 2022) continued to deliver, and several were deployed on long Towed Array Patrol Ship (TAPS) duties.

Hythe Engineering maintenance work aboard HMS Kent

Led by our experienced manager Simon Pay, Hythe Engineering undertook a variety of works on board HMS Kent. There was a mixture of manufacturing new parts, as well as maintenance and replacement depending on age and performance. 

Specifically, the team carried out steelwork installation, electrical removals and installs, constructive removals, constructive pre-fabrication, and constructive installation, as well as painting, lagging and scaffolding. 

There were tight deadlines in place which posed challenges to Simon and the team, but they planned the project well and determinedly met their required schedule. In the end, the Type 23 class team were thrilled with the work. 

 

What is Fleet Operational Sea Training?

Led by the Royal Navy’s ultimate trainers and assessors, Fleet Operational Sea Training (FOST) is responsible for ensuring that Royal Navy and Royal Fleet Auxiliary vessels are fit to join the operational fleet. 

The training package has undergone some substantial changes in the past few years, with the emphasis increasingly on shorter, bespoke training packages and assessments depending on a ship’s mission such as submarine hunting, board-and-search patrols, and task group duties. 

In the Summer of 2022, Kent successfully completed FOST ready for Autumn deployment. Kent is due to begin FOST again this spring (2023). 

 

Head to our projects page for more like this.

 

HMS Lancaster left Portsmouth on the 22nd of August, with no plans to return until at least 2025. While docked in the naval base, Lancaster underwent maintenance work and upgrades in preparation for its extended mission. Hythe Engineering was contracted by BAE Systems to carry out a number of engineering projects on the vessel between May and July last year.

HMS Lancaster’s Extended Mission 

As the second major Royal Navy warship to operate out of Bahrain on a three-year security mission, Lancaster will replace HMS Montrose in the Gulf working with Allies and regional partners. The mission involves providing security to the UK and international shipping, and preventing the proliferation of arms and drug smuggling which directly impacts the security of the Middle East and Europe.

Once in Bahrain, the 200-strong crew – including a Royal Marines boarding team and Wildcat helicopter flight – will trade places like-for-like with a second crew in the UK every four months.

Known as ‘forward deploying’, it spares ships the month-long voyage to and from the Middle East, allowing more time to be spent on patrol, with maintenance carried out in the Gulf rather than back in the UK.

Hythe Engineerings’ Work on HMS Lancaster

Headed up by project manager Matthew Harbord, a team of eleven from Hythe Engineering successfully completed maintenance work on the Royal Navy warship. 

Our engineers completed a range of capabilities, including fabrication, welding, pipework, electrical fitting, reconfiguration and various upgrades. The crew will be particularly pleased with the interior accommodation upgrades and improvements, and capability insertions in the hangar. 

The work was delivered on budget, and within the tight timescales to get HMS Lancaster sailing again.

 

Hythe Engineering and the Royal Navy

Hythe Engineering has an established history of working to support the Royal Navy and the Ministry of Defence. Based in the Portsmouth Naval Base, we are in a prime position to help out with responsive projects as well as long-term maintenance works on docked vessels. Our rich experience with marine engineering has allowed us the opportunity to work on a number of Her Majesty’s vessels.

Although some of the work we do is classified, there are some projects we’re allowed to talk about. Take a look at some of our naval case studies below. 

• HMS Kent
• Reactive response work on active Royal Navy vessel
• Hythe Engineering team up with HMS Queen Elizabeth for a pit stop  

Get in touch with our team to discuss your next  engineering project. 

 

When Royal Navy vessels are on deployment, any necessary marine engineering and maintenance work requires prompt and accurate reactivity. 

In the summer of 2022, the Hythe Engineering team responded to a request from BAE Systems regarding a Type 45 Destroyer. The ship was operating in the Mediterranean and the Baltic and further south in the Med alongside HMS Albion’s task group. 

Working with NATO allies and partners, the vessel completed a successful European security mission. While in deployment, the vessel had multiple short-notice activations and has been involved in three major operations across 2022. 

“Britain’s six Type 45 Destroyers are among the most advanced warships ever built. They’re suited to a huge range of tasks, from hunting down pirates to defending the Fleet from air attack, or providing humanitarian aid. 

Equipped with the ferocious Sea Viper missile, which can knock moving targets out of the sky from up to 70 miles away, Type 45 Destroyers are the backbone of the Royal Navy.” 

• Royal Navy

At the time of the request, the vessel was located in Souda, Crete. Ensuring our team can be globally deployed to complete necessary work allows us to be flexible enough to assist with maintenance projects at any location. The marine engineering carried out by the Hythe Engineering team allowed the Destroyer to carry on with its operations without the need to return to the Portsmouth Naval Base, saving the vessel and crew crucial time. 

Completing the project alongside BAE Systems were two Hythe Engineering Mechanical Fitters. The team were able to complete the maintenance work with basic hand tools. This meant the project could be completed quickly and with as little disruption as possible to the active Destroyer. 

Greg Strange, the project manager, commented, “I believe Hythe Engineering was selected for this project because our ability to provide rapid response services was well-suited to this quick turn-around project, along with the skillset of our personnel.” 

While completing the project, our Mechanical Fitters also assisted on a few other minor projects onboard the Destroyer. They kept the client up to date with daily discussions whenever they were required and were helpful and proactive with the general running and coordination of the project.

Hythe Marine Services and BAE Systems teamed up to provide an exceptional work experience opportunity for the next generation of marine engineers. Through the Sea Angling Classic event, apprentices got to work together to create a stunning, historical, masterpiece. 

“Two reputable, respected companies came together to provide exceptional work experience for the next generation of marine engineers.” – World of Angling Spirit 

Through a longstanding partnership between BAE Systems and Hythe Marine Services, apprentices are often given incredible opportunities to work on important real-life projects, such as for the Royal Navy. This collaboration was taken one step further through the Sea Angling Classic event where the apprentices worked together to use materials from some of the most iconic vessels of our time to create what can only be described as a stunning masterpiece.

“Whoever wins this trophy will not only be taking home a piece of history but a clear and present representation of the skills Hythe Marine Services and BAE Systems are building as the talent of tomorrow.”

 

What did the project involve?

The largest consideration in creating this trophy was that everyone involved wanted the final piece to stand out and have a high standard of detail and craftsmanship from every angle. Similar to the construction of a Naval ship, there were multiple teams providing support, right down to the smallest of tasks. There were points within this project where efficient project management was required in order to meet the deadline. 

Through the dedication and hard work from different areas of both organisations, including joiners, machine operators, engravers, constructors, fabricators, welders, plus sub-contracted polishers, everything came together to deliver the trophy on time.

History and Heritage 

Alongside 250-year-old timber, resin inlay, stainless steel, mahogany, and a range of other metals, materials in the trophy are taken from heritage and serving Royal Naval vessels: 

• The round bar is made of recycled material from the HMS Prince of Wales. 
• The stainless is an offcut from works on HMS Prince of Wales.
• The oak and copper are salvaged from the HMS Victory’s refurbishment. 

So much hard work, dedication and commitment were put in by so many people to create this trophy. And as a result, it’s so much more than just a trophy. It symbolises the historic maritime city of Portsmouth. It showcases the world-class workmanship of BAE Systems and Hythe Marine Services. And it’s showing the engagement from the historic dockyard and everybody involved here. There’s been so much hard work from everybody behind the scenes to create something extra special for Portsmouth. 

Portsmouth is of course world-renowned for being the maritime city that it is, and what we’re aiming to do is highlight the vibrant city and how much is going on here. So for this trophy to be made out of the artefacts from HMS Victory and the aircraft carriers is incredible. To be allowed to use the mayor’s crest on the trophy is a real honour, and the finished trophy will now be seen worldwide.

For more information about Hythe Marine projects, or to speak with our experts for support, please contact us here.

 

Hythe Marine Services serve the marine industry with anything from fast-response one-off projects to long term customers. One example of the latter is with Tall Ships Youth Trust. Over the past eight years that we’ve worked with them, we’ve built a great relationship.

In this case study, we share some of the great work done by Tall Ships Youth Trust and take you through how we collaborated with the charity to solve a recent problem.

 

Who are Tall Ships Youth Trust?

Tall Ships Youth Trust is the UK’s oldest and largest youth development sail training charity. With a particular focus on working with young people from disadvantaged backgrounds, they’ve been providing young people aged 12-25, with life-changing experiences at sea for 65 years.

During this time, more than 120,000 young people have experienced a transformational adventure, sailing over two million nautical miles with the charity – equivalent to sailing around the world 92 times! They currently operate five vessels, four 72ft Challenger yachts and a 55ft ketch.

The Challenger yachts undergo surveys to keep them maintained, which on a recent occasion alerted them to an issue. A repair was required, so the team reached out to Hythe Marine Services to complete the work. 

What did the Project Involve?

Throughout our time working with Tall Ships Youth Trust, they have primarily engaged our team to replace sections of the steel hulls on their Challenger yachts as needed. Most recently this has been on Challenger 1 and Challenger 2. During their five-year coding renewal surveys, they found steel corrosion below the minimum allowed.

Speaking on the work completed, John Farndell, Operations and Maintenance Manager at Tall Ships Youth Trust, said: 

“We have always found Hythe Marine Services (HMS) responsive and ready to assist. We work together to come up with the most efficient and effective method for repairs, which sometimes need a little creativity.

After the first completed works, our surveyors were happy with the standard of work delivered. The knowledge that HMS is doing the work also makes the sign off process simple and quick, especially with the comprehensive reports they provide.

He added: “Safety is critical to the work we do and I know that when hull sections are replaced, the young people we take to sea and develop are safer than they were before.”

John also commented on how our ability to provide in-house non-destructive testing sped up the process and added an extra layer of quality assurance. 

“It’s great that HMS can now do the required non-destructive testing (NDT) of the welding work themselves, which saves time and allows us to start painting sooner without compromising quality.”

 

Our engineers work with you to solve your problems by creating a bespoke turnkey solution. Get in touch to collaborate on your next project. 

As bespoke design engineers, Hythe Marine Services’ (HMS) never shy away from the less ordinary. And a recent star-studded industrial-style decor project for a brand new London wine bar definitely falls under this category.

Actor, DJ and producer Idris Elba has embarked on an exciting venture to open a wine bar, Porte Noire, in London’s King’s Cross. He’s taking on the challenge alongside his business partner, David Farber, founder of Connaught Wine Cellars.

Read on to find out about how HMS first got involved with Porte Noire, and all the work that went on to complete the project.

 

The Porte Noire Industrial-style decor Project

The Porte Noire bar is an extension of Idris and David’s existing Porte Noire Champagne and rosé brand that launched in 2018. The venue boasts ‘one of the largest fine wine tasting rooms in London’.

Porte Noire got in touch with the HMS team looking for bespoke planter boxes that would be on display at the front of the bar. The project request was for the planters to have a modern, industrial look and feel, to complement the bar’s rustic-meets-contemporary interior.

“We’re really excited to be bringing a slice of continental hospitality to London this autumn. Since launching our brand Porte Noire, we have seen some incredible reviews of the product and we’re looking forward to creating a space to match.” 

– David Farber, Porte Noire, speaking on the extension of the brand and launch of the wine bar

Creating the industrial-style decor planters involved mostly HMS’ metalwork capabilities. The team worked from a set of supplied drawings which they used to shape, measure and weld the boxes. Working closely with David Farber of Porte Noire and Timothy Block of London Wine Cellar, the HMS team successfully completed and installed the planter boxes.

To complete the project, the team used their welding, fabrication, and plating capabilities. And to help diversify their skills, two HMS apprentices were involved throughout the project.

 

The Project’s Challenges

In their initial designs, Porte Noire were looking for the planters to feature one single pane of curved glass. Unfortunately, this design would’ve led to a major expense and a much longer timescale. With the launch date fast approaching, this was not an option. The compromise was to instead use three panes of glass, which both the client and HMS were more than happy with.

Of course, large metal boxes aren’t particularly easy to manoeuvre. Particularly in busy Central London! The installation brought up some issues for the team. Most notably, there was no way to get a crane in to lift the boxes into place. The team solved this issue by delivering as close as they could to the venue, then using specialised lifting trollies to physically lift them into place.

 

The Wins

Although the company is born out of the marine industry, working on varied projects like this one provides a multitude of benefits for the business. It keeps everyone’s creative juices flowing, and keeps them on their toes which in turn ensures their skills stay sharp. Working on a variety of projects also gives apprentices more opportunities to get out into the world and see what their careers may bring them.

The client is more than pleased with the work of the team at HMS, and as a result, are in touch about future potential projects.

 

Get in touch with our team to discuss your next project.

Director of Value Engineering Luke Fitzgerald recently designed and built a bespoke fishing bait station for a boat.

 

After noticing a gap in the market for a catch-all storage and bait station, Luke Fitzgerald set about creating a custom solution.

 

As Director of Value Engineering at Hythe Marine Services (HMS), Luke has extensive experience in fabricating bespoke solutions for the marine industry. He leads the team on anything from small-scale projects to supporting the Navy’s warships and composites for luxury superyachts.

And as a keen fisherman, he knew there was nothing widely available that would be suitable as a customisable solution for a fishing rack. As a result, Luke created a bespoke fishing bait station from scratch – a completely custom design to suit the boat and the needs of the fishermen.

 

What Was The Problem?

Nobody is selling tailored bait stations, so bespoke boat storage is hard to come by. He told us, “Bespoke custom-made boat equipment and things like that just aren’t on the market.”

The aim was to create a fishing workstation that would fit a toolbox, fishing rod holders, a chopping table, and all the necessary equipment and organisation in one place.

Find out about the HMS team’s experience with boatbuilding in our related article: The World of Luxury Yachts and Traditional Boatbuilding.

 

The Solution

Nothing like this existed for the customer’s Offshore 2000 fishing boat. And so, Luke wanted to create a central workstation that would tailor to every need when out fishing. Spending his free time fishing in coastal waters, as well as offshore fishing targeting wrecks and sandbanks, Luke knew this one-stop-shop would provide more time to enjoy the actual fishing.

With a career in fabrication, Luke knows what he’s doing when it comes to bespoke solutions for boat owners. He explained, “I’ve done a few similar projects in the past. With custom solutions, pretty much anything the customer dreams up for their boat can be made. The sky’s the limit.”

 

 

Using 316L stainless steel tube and fitting, he designed, constructed and fit this custom-made fishing bait station.

 

The Process For Building A Bespoke Fishing Bait Station

These bespoke units are very appealing to boat owners, marinas, and anybody with an interest in fishing or the marine industry. We asked Luke what the process would look like for customers interested in a similar solution.

He explained, “We can make anything they want, so finding out what their needs are is the first step.”

Once the team has a good idea of what the customer is looking for from their bespoke unit, they can work backwards from there. The Hythe team will then produce a drawing and use CAD software to get the dimensions and create a 3D image of what it will look like.

This enables the customer to visualise the unit in their own boat. Finally, the customer approves the look of the design, before the team begin the work.

 

 

Of course, no project like this would be complete without testing out the fishing bait station in person! So Luke and MD, Josh Mathias, went out and tried it out, purely for product testing purposes of course!*

*Hythe returned all catches to the sea.

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