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Austal USA’s production facilities, comprising of almost a million square feet of manufacturing floor space, are organized into three main sections:
- Module Manufacturing Facility (MMF)
- Final Assembly
- Vessel Completion Yard
Module Manufacturing Facility (MMF)
The completed Module Manufacturing Facility (MMF) houses a 17-acre, fully-covered, manufacturing facility with two fully commissioned production lines. The facility is supplemented by a 1.7-acre drive-through warehouse for the storage of equipment and materials and parking for over 2,000 employee vehicles in a secure, paved and fenced area.
Throughout the MMF, we use technology to improve our manufacturing standards. Our manufacturing operations begin with Computer Numerically Controlled (CNC) router cutters, to cut nested shapes from aluminum plate. Router cutters cut a neat edge, removing the need to de-burr cut parts. The router cutters are complimented by twin gantries allowing for the cutting of two plates simultaneously.
CNC extrusion cutters receive information from our 3D modeling software to cut stiffeners to length and prepare the ends for joining. We make extensive use of complex extrusions to optimize vessel structure, and partner with suppliers to optimize parts for Friction Stir Welding, an automated process that gives higher quality while reducing manual labor.
Our pipe shops feature CNC pipe benders and a tee-forming machine, reducing the quantity of welded fittings used and speeding production.
The Final Assembly Yard consists of two (134ft x 400ft) assembly bays, one (135ft x 425ft) and one (90ft x 360ft) for module fabrication/erection and component storage. Each bay is equipped with overhead cranes each capable of lifting 40-ton modules, and the three larger bays include mezzanine levels for shop space, material storage, and small assembly fabrication.
Vessel Completion Yard (VCY)
Austal’s latest expansion project is the Vessel Completion Yard (VCY), a 36-acre secure fenced parcel at the northern tip of Pinto Island. The VCY will have a protected 1,000ft long x 300ft wide slip with four wet berths, two on each side of the slip. The reinforced concrete bulkheads surrounding the slip will have services for our constructed ships for their completion, trialing and delivery, as well as providing heavy weather mooring and protection for these ships. Austal plans to build a 20,000 sq ft production building with associated administrative space, 5,000 sq ft warehouse, and paved parking for 400 cars. The VCY has 1,500 feet of waterfront along the Mobile River along with sufficient space for either storage of large shipyard equipment or any future facilities.