Introduction
When outfitting a large catamaran for bluewater cruising, one of the most significant decisions you will make is choosing the right sail material. The fabric you select will dictate not only the cost of your sails but also their performance, longevity, and how they handle the immense loads generated by a multihull.
At Kraken Sails, we frequently consult with owners who are torn between the traditional reliability of woven Dacron and the modern performance of cruising laminates. Both materials have their place in the offshore world, but they cater to different priorities. In this post, we will demystify these two primary categories of sailcloth, exploring their strengths and weaknesses to help you make an informed decision for your catamaran.
The Workhorse: Woven Dacron
Dacron is the trade name for woven polyester sailcloth. For decades, it has been the undisputed king of cruising sails. The manufacturing process involves weaving polyester yarns tightly together and then treating the fabric with heat and resin to lock the weave in place and reduce stretch.
Premium Dacron for Catamarans
Not all Dacron is created equal. For a large, heavy catamaran heading offshore, standard production-boat Dacron will quickly stretch out of shape. You need premium, high-tenacity Dacron designed specifically for high loads. Fabrics like Challenge Fastnet or Contender Supercruise are engineered with thicker yarns and tighter weaves to withstand the punishment of bluewater sailing.
The Pros of Dacron
- Exceptional Durability: Dacron is incredibly tough. It can handle flogging, chafe, and rough handling better than almost any other material. It does not suffer from delamination, a common failure mode in older or cheaper laminates.
- Longevity: A well-made Dacron sail can last for 10 to 15 years, or even longer, making it a very cost-effective choice over the long term.
- Ease of Repair: If you tear a Dacron sail in the middle of the Pacific, you can often repair it yourself using a heavy-duty sewing machine or even by hand with a palm and needle.
The Cons of Dacron
- Stretch: The biggest drawback of Dacron is that it stretches over time. As the sail stretches, it loses its designed aerodynamic shape, becoming fuller and deeper. This increases heeling force (or in a catamaran, stress on the rig) and reduces pointing ability upwind.
- Weight: To achieve the strength required for a large catamaran, Dacron sails must be built from heavy cloth, making them difficult to hoist, flake, and handle short-handed.
The Modern Alternative: Cruising Laminates
Laminate sailcloth is constructed by sandwiching a load-bearing grid of fibers (such as polyester, Kevlar, or carbon) between layers of Mylar film. For cruising laminates, protective layers of woven taffeta are added to the outside to protect the film from UV degradation and chafe.
Cruising Laminates for Catamarans
Modern cruising laminates, such as Dimension Polyant DCX or Contender CDX, use a polyester fiber grid and robust taffeta outer layers. These materials offer a significant performance upgrade over Dacron while maintaining respectable durability for offshore use.
The Pros of Laminates
- Superior Shape Retention: The primary advantage of laminate sails is their resistance to stretch. The internal fiber grid locks the sail’s shape in place, meaning your sail will maintain its efficient aerodynamic profile for years. This translates to better pointing upwind, less drag, and a faster, more comfortable ride.
- Weight Savings: Laminates are stronger for their weight than Dacron. A laminate sail will be significantly lighter than a Dacron sail of the same strength, making hoisting, reefing, and stowing much easier for a short-handed crew.
- Performance: For catamarans over 45 feet, where loads are immense, the shape-holding properties of laminates become increasingly important to maintain the boat’s performance potential.
The Cons of Laminates
- Delamination and Mildew: While modern manufacturing techniques have vastly improved, laminates can still suffer from delamination (where the layers separate) over time, especially in hot, humid climates. Moisture trapped between the layers can also lead to mildew growth, which is unsightly and difficult to remove.
- Lifespan: Laminates generally have a shorter lifespan than premium Dacron. While they hold their shape perfectly until the end, they tend to fail suddenly when the materials degrade, rather than slowly stretching out of shape like Dacron.
- Repair Difficulty: Repairing a torn laminate sail offshore is more complex and often requires specialized adhesive tapes rather than simple sewing.
Making the Choice for Your Catamaran
So, which material is right for your bluewater catamaran? The answer depends on your cruising style, budget, and the size of your boat.
If your primary goals are maximum durability, longevity, and budget-friendliness, and you are willing to accept a gradual loss of sail shape and performance, then a premium woven Dacron is an excellent choice. It is the true “set and forget” workhorse of the oceans.
However, if you own a larger catamaran (45 feet and above), value performance, want to sail closer to the wind, and prefer lighter sails that are easier to handle, a modern cruising laminate is the superior option. The shape retention of laminates will transform how your boat sails, making passages faster and more enjoyable.
At Kraken Sails, we work closely with you to analyze your specific needs and recommend the perfect material. In our next post, we will explore a third option that bridges the gap between Dacron and laminates: Woven Dyneema, often considered the holy grail of bluewater cruising fabrics. Contact us today to discuss your catamaran’s sail plan!
Kraken Sails – Engineered for the Ocean.