Program Overview
In June 2017, Birdon was awarded a $5M contract by the Department of Defence to disassemble and recycle the Ex-HMAS Sydney, a 3,000-tonne guided missile frigate. The project involved the removal of dangerous goods, recovery of valuable materials and secure dismantling in compliance with ITAR and other regulatory frameworks.
The vessel was towed from Sydney Harbour to the Common User Facility (CUF) in Henderson, Western Australia, where the work was completed by May 2018.
Quick Facts
- Client
Department of Defence CASG
- Location
Australian Marine Complex (AMC), Henderson, WA
- Lifecycle Stage
Decommission
- Asset
Ex-HMAS Sydney – 3,000-tonne Guided Missile Frigate
- Timeline
June 2017 – May 2018
Objectives
- Safely dismantle and recycle the Ex-HMAS Sydney
- Project must be completd in Australia
- Maximise material recovery and minimise environmental impact
- Comply with national and international regulations including ITAR
Challenges
- Handling and removal of dangerous goods and waste materials
- Managing structural instability during dismantling
- Coordinating logistics for towing and land-based dismantling
- Ensuring accurate environmental reporting and compliance
Birdon’s Approach
Birdon executed the project through a structured six-phase methodology to ensure safe, compliant and efficient delivery.
The process included receipt and preparation of the vessel at the Common User Facility, followed by pre-dismantling setup including sorting systems and disposal chute installation. Hazardous waste was identified and safely removed prior to dismantling.
Valuable metals were segregated and recovered, with non-ferrous materials processed for recycling. Final dismantling of the hull and superstructure was completed using hydraulic shears, followed by site restoration, documentation and issuance of a Certificate of Destruction.
Outcomes & Impact
The project achieved a 95% metal recycling rate, with materials reused within Australia, supporting domestic recycling and supply chains.
The program generated employment for 20 local workers and multiple subcontractors, contributing to regional economic activity.
All works were completed with zero environmental incidents and with accurate reporting of environmental and economic outcomes through domestic recycling partnerships.
At the completion of the project, Birdon were awarded the project for the Deconstruction & recycling of ex HMAS Darwin, another Guided Missile Frigate.
Testimonial
“Birdon’s commitment to environmental protection and sustainability, combined with its technical expertise, made this project a success. The accurate reporting and local economic impact are commendable.”
John O’Loughlin
Director CSC, Capability and Sustainment Group, Department of Defence
Capabilities in Action
- Large-scale naval vessel decommissioning and dismantling
- Hazardous material identification, handling and disposal
- Metal recovery, segregation and recycling at scale
- Structured multi-phase project delivery for complex assets
- Compliance with ITAR and national and international regulatory frameworks
- Delivery of sustainable outcomes with high material recovery rates
