In 2023, Australian shipbuilder Birdon expanded its American operation, acquiring a 32-acre shipyard in Bayou La Batre from Metal Shark Boats. The facility’s existing infrastructure and proximity to the Gulf made it an ideal location to build and deliver a fleet of 27 new Waterways Commerce Cutters (WCC) for the U.S. Coast Guard (USCG).
Birdon was awarded a $1.187 billion contract to design and construct the vessels in 2022.
The shipyard, which belonged to Horizon Shipbuilding before it was taken over by Metal Shark Boats, already featured more than 1,700 feet of waterfront, a 660-ton Travelift and multiple cranes, as well as five steel buildings for fabrication and construction.
“The site allows for in-house construction of both hull and superstructure, reducing technical risk and improving schedule control,” says Sandra Armstrong, Birdon’s director of communication and external relations.
In preparation for construction, Birdon made early investments in engineering and design, working to procure long-lead time materials by collaborating with carefully chosen U.S. subcontractors. Birdon has committed to more than $27 million in capital improvements to transform the Bayou La Batre site into a Tier 2 shipyard that can build up to six vessels simultaneously. The shipyard has received an updated USCG certification to handle vessels up to 589 long tons, expanding its operational capabilities.
The new WCC vessels will replace the USCG’s aging inland fleet. These vessels support the USCG as it maintains and protects the U.S.’ intra-coastal and inland Marine Transportation System (MTS). The MTS spreads across the 12,000 miles of commercially active inland waterways including the Mississippi River, the Great Lakes, the Columbia-Snake River system, and the Gulf and Atlantic intercoastal waterway.
Each year, 630 million tons of cargo move through these waterways, accounting for more than $5.4 trillion in economic activity and supporting 30.7 million jobs for the U.S. economy. WCCs establish and maintain more than 28,200 aids to navigation (ATON) that help ensure the safe and efficient flow of maritime commerce. Additional WCC missions include search and rescue, marine safety, marine environmental protection and security of ports, waterways and coasts.
The WCC contract includes 16 river buoy tenders (WLR) and 11 inland construction tenders (WLIC) — two separate but related vessel designs. Designed for dynamic river conditions, the 180-foot-long WLR is used to set, relocate and recover buoys on rivers. The WLIC measures 160 feet in length and is equipped to construct, repair and maintain fixed ATON, such as beacons. The only USCG platform capable of pile driving, the WLIC can erect towers and perform major structural repairs. Each vessel accommodates a crew of 17 and has an endurance of 11 days.
“Many of the current inland waterway’s fleet are more than 50 years old and are increasingly difficult and expensive to maintain,” says Armstrong. “The new WCCs will greatly enhance the Coast Guard’s ability to perform their MTS missions.”
Birdon’s WCC program incorporates 3D modeling and integrated logistics support systems to streamline design, maintenance and lifecycle management. In alignment with the USCG’s sustainability goals, the vessels are designed with fuel-efficient propulsion systems and reduced emissions.
“Birdon is using modular construction techniques to improve efficiency, quality control and scalability,” says Armstrong. “This approach allows different sections of the vessel to be built simultaneously and then assembled, reducing build time.”
All construction work on the WCC vessels will take place in Alabama.
In July 2023, Birdon announced that 98% of its suppliers are U.S. companies, and 70% of the contract will be performed by small businesses. Many of these smaller companies are located on the Gulf Coast.
“We are thrilled to be working with local subcontractors such as Kern Martin in Coden, Alabama; Hiller Systems in Mobile, Alabama; Techcrane International in Covington, Louisiana; Beier Integrated Systems in Gray, Louisiana; and LeBlanc & Associates, based in Houma, Louisiana, with an office in Bayou La Batre,” Armstrong says.
Birdon employs more than 100 people in Bayou La Batre, and the company plans to create several hundred additional jobs over the next three years as part of its expansion.
“Birdon has made workforce development and community engagement central to its operation in Bayou La Batre, particularly through its Birdon Futures Apprenticeship Program and partnerships with local institutions,” says Armstrong. Developed entirely in-house, the two-year apprenticeship program is designed to prepare participants for successful long-term careers within the industry. Participants are paid and can earn National Center for Construction Education and Research (NCCER) certification.
This fall, Birdon was reviewing applications to select 10 local apprentices to receive hands-on career training and practical instruction in shipfitting, welding and fabrications from experienced mentors. Birdon also collaborates with community colleges and high schools to encourage the next generation of skilled workers.
“Birdon continues to invest in innovation, talent development and strategic partnerships to support its mission of delivering whole-of-life solutions across its industries,” says Armstrong.
Birdon was founded in Port Macquarie, New South Wales, Australia, in 1977 as a family-owned business. Over the years, the company has grown into a diversified global group serving the maritime, military and resource sectors with operations in Australia, the U.S., Europe and Asia.
Since entering the U.S. market in 2009, Denver, Colorado-headquartered Birdon America Inc. has partnered with U.S. government agencies, including the Department of Defense and the Department of Homeland Security. In the U.S., the company operates through four main business divisions: Marine Shipbuilding and Repair, Disposals, Engineering and Marine Propulsion. Birdon is currently delivering major projects for the Army and Navy, in addition to the USCG.
Birdon’s U.S. operations are led by President Tony Ardito, an experienced maritime industry professional who held previous roles at BAE Systems and Austal USA. Ardito is the executive in charge of the WCC program. Director of Programs/General Manager Hoby Swiney oversees day-to-day operations in Bayou La Batre, including shipbuilding, workforce management and operations. Armstrong leads Birdon’s community engagement, public affairs, and strategic partnership efforts in the U.S. She works to build relationships with local institutions, promotes workforce development initiatives and leads U.S. government relations initiatives.
In June, Birdon began work on the first WCC. “Our entire team is thrilled to be entering this next phase of the WCC program with the start of construction,” Ardito says.
Capital investments currently underway at the shipyard include a 56,400-square-foot steel processing and fabrication facility, a 10,945-square-foot blast and paint facility, and two 19,320-square-foot final assembly buildings. Birdon plans to construct the 27 WCC vessels within a 10-year period, generating a significant economic impact for Bayou La Batre and reinforcing the region’s role in the maritime industry for years to come.
Kathleen Farrell and Mike Kittrell are Mobile-based freelance contributors to Business Alabama.
This article appears in the November 2025 issue of Business Alabama.
