A few weeks ago, John Delaney, president of Seattle-based Windstar Cruises, stood on a scaffold at a historic shipyard in Palermo, Italy, and took a blowtorch to the Star Breeze, a 30-year-old, 212-passenger motor yacht.

With sparks flying, and shipyard workers and invited guests cheering him on, Delany made the final vertical cut to chop Star Breeze in half. But he was hardly destroying the small ship—he was doing just the opposite.

In a process called “stretching,” the Star Breeze is getting pulled apart to make room for a new, 84-foot, 1,250-ton prefab midsection addition. Think of it like unsnapping (or unwelding) two Legos and putting another block in between. But with a boat.

After four months of surgery, the all-suite Star Breeze will be bigger, more luxurious, and more profitable. When she debuts again in February, she’ll have 50 new suites to house 100 additional guests, a 50% increase in passenger capacity, and command higher rates for her shiny new cabins. Delaney says it should add at least 20 years to the ship’s life span.

Stretching, it turns out, is so good for Windstar’s bottom line that the company will similarly expand two more ships by the end of 2020, spending a total $250 million to increase its overall capacity by 24%.

The Big Idea
Stretching cruise ships is hardly a new idea. Teijo Niemela, editor of CruiseBusiness.com, says the concept was borrowed from Scandinavian ferries that were sliced to add cargo space. He sailed on his first stretched ferry in Finland in 1972.

It was only six years later that Royal Caribbean added an 85-foot block to first expand a ship, the Song of Norway, starting a slow but steady industry trend. The defunct Royal Viking Line stretched ships in the 1980s; Norwegian Cruise Line added sections to three ships in the 1990s. More recently, MSC Cruises lengthened four ships and has announced plans to slice a fifth. The $143 million project, scheduled for 2021, will add 75,000 square feet to the MSC Magnifica, comprising 215 new staterooms (most of them in the popular balcony category), two restaurants, and a water park, as well as technology that’s more environmentally friendly.

Last year in Palermo, ultraluxury line Silversea added a 49-foot midsection to its Silver Spirit at a cost of $70 million, increasing the ship’s capacity from 540 to 608 passengers by adding 34 suites. It took 500 workers and about 450,000 man hours to complete the stretch.

“For cruise lines, it’s a quicker way to expand capacity compared to building a new cruise ship,” Niemela says. “A new cruise ship takes about 22 months or more [to build]. Add a new midsection, and it’s only a few months that the ship is out of service.”

Doing the Math
With estimates of about $175 million to build a 300-plus passenger vessel, stretching the older ones made more sense, Delaney says, especially when each project costs an average $80 million.

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