The construction of an IMOCA—a 60-foot monohull designed to tackle the world’s oceans solo is a complex, resource-intensive process. From carbon fibre and resins to metals and various consumables, a single build generates tonnes of waste, much of which is difficult to recycle. However, in the face of ecological urgency, teams like Armel Tripon’s and the association Les P’tits Doudous are proving that it’s possible to reconcile high-performance sailing with environmental responsibility.

Through the construction of their new IMOCA, the team implemented an innovative waste management system aimed at reducing, reusing, and recycling as many materials as possible. This pioneering approach could inspire the entire nautical industry.

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The Challenge: Complex Waste with Little Value

Alarming Figures

According to a study by the IMOCA Class, building a hull and deck generates 5.9 tonnes of waste for just 2.8 tonnes of final structure. This waste includes:

Carbon fibre (prepreg, cured, dry fibres)
Resins and adhesives
Work environment materials (tarpaulins, felts, grids, fabrics)
Consumables (gloves, masks, tapes, packaging)
Metals (stainless steel, titanium, lead)

Until now, much of this waste ended up landfilled or incinerated due to a lack of suitable recycling channels—yet many materials could be reused or repurposed.

Structural Barriers

Material complexity: Waste is often composite (contaminated plastics, multi-material), making recycling difficult.
Insufficient volumes: Recyclers require minimum quantities (e.g., 400 kg of compacted polystyrene), which are hard to achieve for a single yard.
Lack of local solutions: Few actors offer dedicated channels for offshore racing waste.

Faced with these challenges, the P’tits Doudous team decided to take action.

An Innovative Approach: Mapping, Sorting, and Valorising Waste

Mapping Waste for Better Management

From the start, the team identified and quantified each type of waste, collaborating with circular economy experts (Sail of Change, EVEA). The goal: to understand waste streams and find tailored solutions.

Source Sorting: A Collective Commitment

10 dedicated bins were placed near workstations.
Team training: Operators were educated on sorting, adding an estimated 7.5 minutes per person per day—an effort rated 8.2/10 in an internal survey.
Compaction and storage: Waste was compacted and stored in a 20-foot container before being sent to specialised channels.

Valorising Each Stream: Key Partnerships

The team partnered with innovative actors to recycle or reuse waste:

Waste Type	Partner	Valorisation Solution
Tarpaulins & felts	Airtech	Recycled into automotive parts or insulation (e.g., 1,152 kg of tarpaulins/felts sent).
Separators (wadding, PE)	Biotop	Transformed into insulation or reinjected into new materials (270 kg valorised).
Carbon offcuts	Karbon Creations	Made into objects (bracelets, keychains) or SRF (Solid Recovered Fuel).
Metals (stainless steel, titanium)	Local scrap dealers	Resold to benefit the P’tits Doudous association.
Used sails	Second Souffle (All Purpose)	Reused in upholstery or recycled into new textiles.
Polystyrene	Biotop / Knauf	Integrated into tide bins or insulation (if volumes sufficient).

Result: 49% of waste was valorised (compared to a 10% industry average), totalling 2.9 tonnes out of the 6 tonnes generated during construction.

Outcomes and Lessons: A Model to Replicate

Positive Environmental and Human Impact

Emissions reduction: Using recycled carbon (65% of the hull) cut greenhouse gas emissions by a factor of 7 compared to virgin carbon.
Team engagement: Operators welcomed the initiative, finding added meaning in their work.
Industry inspiration: Other yards (Duqueine, Windelo) and organisations (IMOCA Class, Fédération des Industries Nautiques) are now exploring this methodology.

Ongoing Challenges

Cost and logistics: Waste management accounted for 0.89% of the boat’s total budget (~€53,000), mainly for labour (sorting, transport, coordination).
Technical limits: Some waste (resins, adhesives, contaminated consumables) still lacks recycling solutions.
Need for collaboration: To make recycling viable, volumes must be scaled up by pooling multiple yards.

Next Steps

Shared platform: A dedicated structure for collecting and sorting waste from Breton boatyards could optimise costs and transport.
More recyclable materials: Work with manufacturers (Airtech, Diatex) to design single-material or reusable work environments.
Regulatory adaptation: The IMOCA Class could mandate minimum waste valorisation rates for new boats.
R&D support: Fund studies on resin and multi-material composite recycling, in partnership with actors like Fairmat or Extracthive.

Conclusion: A Path Forward for Offshore Racing

The IMOCA Les P’tits Doudous experience shows that a circular economy is achievable in offshore racing, provided that:

All stakeholders (yards, recyclers, institutions) are involved.
Innovative partnerships (manufacturers, eco-businesses, artisans) are forged.
An initial cost premium is accepted for long-term environmental and social benefits.

What’s next? Imagine a nautical industry where 100% of composite waste is valorised, thanks to shared logistics and advanced recycling technologies. An ambitious goal, but within reach if all actors mobilise together.

→ For more information (in French):

This report was produced by Pauline Gérardin and the entire IMOCA P’tits Doudous team.

Sailing Voile de compétition Imoca

Waste Management in Offshore Racing: How the IMOCA Les P’tits Doudous Tackles the Circular Economy Challenge