Australia-based shipbuilder Austal has officially opened its new Modular Manufacturing Facility (MMF), equipping its US shipyard with the ability to build up to three 100 metre-plus vessels each year.
Phase One of the new US$88 million facility comprises 35,000 square metres of manufacturing space under one roof, including a 7,900 square metre warehouse, as well as paved parking for more than 2,000 vehicles.
An official ribbon-cutting ceremony celebrating the completion of Phase One was held at Austal's Mobile, Alabama shipyard on November 10. The event was attended by more than 300 dignitaries, including Alabama Governor Bob Riley, US Navy Programme Executive Officer RADM Bill Landay, US Representative Jo Bonner and City of Mobile Mayor Sam Jones.
"Not only is this significant investment poised to have a positive effect on the surrounding economy, it also gives Austal capacity to facilitate the construction of the US Navy's Littoral Combat Ship (LCS) and Joint High Speed Vessel (JHSV) programmes," said Austal Managing Director, Bob Browning.
The MMF will increase Austal USA's capacity to assemble and outfit unit modules before consolidating them into the full vessel, spreading demands for specific trades more evenly and streamlining the integrated design and production process.
By automating component manufacture, including pipe runs, from a 3D model, Austal is able to assure consistent system configurations across vessels, which benefits operators and makes it easier to operate and support vessels in service.
Austal is also able to provide a safer, more efficient work environment for staff by organising production processes.
The MMF is equipped with routers for the precise cutting of aluminium plate, as well as automated pipe and plate benders. Over 7,000 tonnes of steel were used to erect Phase I of the MMF, while dump trucks moved 23,000 loads of dirt to prepare for the pouring of 23,700 square metres of concrete as the building foundation.
Test constructions are currently underway at the new facility, with work on the US Department of Defence's first 103-metre JHSV scheduled to commence before the end of the year.
As prime contractor, Austal will design and build up to ten JHSVs between 2009 and 2013.
Austal USA is also preparing for US Navy acceptance trials of its 127-metre Littoral Combat Ship, LCS 2 "Independence", which completed builder's trials in October. The vessel is scheduled for commissioning in January 2010.