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In this paper, a new robust adaptive controller is investigated to force an underactuated surface marine vessel to follow a predefined parameterised path at a desired speed, despite actuator saturation and the presence of model uncertainties as well as environmental disturbances induced by waves, wind and sea-currents. To ensure robustness of the path-following controller, time-varying constraint on the off-track error (i.e. the maximal distance from the ship to the reference path) is considered. To address the off-track error constraint the tan-barrier Lyapunov function is incorporated with the control scheme, where the idea of auxiliary design system introduced in Chen, Sam, and Ren (2011) is adopted and its states are used in combination with backstepping and Lyapunov synthesis to adaptive tracking control design with guaranteed stability. Furthermore, the command filters are adopted to implement physical constraints on the virtual control laws so that analytic differentiation of the virtual control laws is avoided. We show that the proposed robust adaptive control law is able to guarantee semi-global uniform ultimate bounded stability of the closed-loop system. Numerical simulations and experimental results are carried out to demonstrate the effectiveness of the proposed algorithm. [ABSTRACT FROM AUTHOR]