Program Overview
Birdon’s Port Macquarie shipyard successfully completed the second docking and full servicing of the Macleay and Manning fuel barges—two vessels up to 64 m in length—on behalf of Serco Defence and the Royal Australian Navy. These dockings occur every five years and represent some of the largest vessels handled at the facility.
Quick Facts
- Client
Serco Defence on behalf of the Royal Australian Navy
- Location
Port Macquarie, NSW
- Lifecycle Stage
Maintain
- Docking Frequency
Every 5 years
- Vessel Length
Up to 64 m
Objectives
- Deliver full lifecycle servicing of Defence Liquid Cargo Vessel
- Maintain vessel integrity and operational readiness
- Support Defence’s regional sustainment strategy
- Strengthen local industry capabilities and workforce
Challenges
- Managing fire risk and hazardous materials during fuel tank servicing
- Coordinating multi-disciplinary engineering, ship repair and safety compliance tasks
- Ensuring safety and efficiency through real-time monitoring
- Meeting Defence maritime standards and classification requirements
Birdon’s Approach
Birdon executed a comprehensive multi-disciplinary scope of work across dry docking, mechanical, hydraulic, electrical and safety compliance systems.
Dry docking works included high-pressure cleaning, abrasive blasting, ultrasonic thickness testing, steel repairs and the application of class-approved coatings across hull, topsides and internal tanks.
Mechanical and propulsion systems were overhauled in accordance with OEM requirements, including engines, shaft lines, propellers, gearboxes and auxiliary systems. Precision machining, fabrication and system integration ensured alignment across propulsion, hydraulic and auxiliary machinery.
Hydraulic systems were serviced through overhaul of deck machinery including cranes, winches and capstans, pressure testing and validation of pumps, valves and accumulators.
Electrical and control systems were load tested, calibrated and upgraded to maintain performance across generation, distribution and automation systems.
Safety and compliance works included servicing of fire detection and suppression systems, certification of lifesaving appliances and overhaul of pollution control systems in accordance with MARPOL and class standards.
All works were completed under class survey, with classification society coordination, functional trials and delivery of updated documentation, logs and certifications to Serco and the Commonwealth.
Outcomes & Impact
The project successfully delivered full servicing of two of the largest vessels handled at Birdon’s Port Macquarie facility, reinforcing Birdon’s position as a trusted Defence sustainment partner.
High-quality outcomes were achieved across mechanical, hydraulic, electrical and safety domains, supporting Serco and Defence’s strategic objective of building regional resilience. The works also enabled cost-effective through-life support and future export capability.
Capabilities in Action
- Multi-trade engineering across hull, mechanical, hydraulic, electrical and control systems
- Delivery of vessel sustainment programs aligned to Defence requirements
- Execution of complex dry docking and tank servicing works
- Integration of propulsion, auxiliary and deck systems
- Compliance with Defence, MARPOL and classification society standards
- Regional shipyard capability supporting workforce development and sovereign sustainment
- Demonstration of high standards of project management, maintenance planning and execution, to meet customers schedule and budget
- Defence, Commercial, State Government and local council requirements
