Program Overview
Birdon is delivering the 47-Foot Motor Lifeboat (MLB) Service Life Extension Program (SLEP) for the United States Coast Guard, one of the nation’s most iconic rescue fleets. This 10-year, USD $191 million program extends the service life of 107 all-weather lifeboats by up to 20 years, ensuring the Coast Guard can continue its mission of saving lives and safeguarding America’s coastline through 2047.
The 47-Foot MLB is designed to operate in surf up to 20 feet and seas up to 30 feet with 50-knot winds, and can self-right after a 180° rollover. Through the SLEP, Birdon is modernising this proven platform with new propulsion, control systems, and structural upgrades while preserving its durability and crew safety.
The program is executed from Birdon’s Portland, Connecticut and Bellingham, Washington shipyards, supporting a dual-coast production model, local supply chains and a growing U.S. workforce.
Quick Facts
- Client
United States Coast Guard
- Lifecycle Stage
Refit / Sustainment (Maintenance)
- Timeline
2019 – 2029 (with contract extension)
- Location
Portland, Connecticut & Bellingham, Washington
- Fleet Scale
Up to 107 vessels
Program Objectives
- Extend the service life of the U.S. Coast Guard MLB fleet through 2047
- Modernise propulsion and control systems to improve performance and reliability
- Enhance crew safety and comfort for high-sea and long-duration missions
- Reinforce U.S. industrial capacity through dual-coast production
- Deliver cost-effective sustainment in place of full fleet replacement
Key Metrics
Vessels
Program Duration
U.S. Jobs Supported
Fuel Savings
Years Extended Service Life
Birdon’s Approach
Birdon delivers full vessel overhauls at its purpose-built Portland, Connecticut facility, supported by concurrent operations in Bellingham, Washington. Each lifeboat is stripped to bare aluminium, inspected, and rebuilt with modernised systems.
Key Upgrades Include:
- New propulsion: Cummins QSC 8.3L 530 hp engines replacing legacy systems, increasing speed and reducing fuel consumption by approximately 35%
- Advanced controls: Glendinning waterproof control systems with automatic rollover reset functionality
- Structural reinforcement: Replacement of fatigue-prone aluminium sections and full hull re-engineering
- Operational refinements: Reconfigured bridge layout, LED lighting, shock-mitigating seating, improved tow systems and maintenance-reducing design features
- A triple-inspection process ensures all systems meet or exceed Coast Guard standards, with each vessel undergoing stability testing and sea trials prior to delivery.
Program Milestones
2019
Contract Award
10-year SLEP contract to extend 47′ MLB fleet life by 20 years
2025
Peak Production
20 MLBs to be refitted across both coasts, sustaining 200+ jobs
2020 – 2023
Production Ramp Up
Facilities established in CT and WA; 27 vessels completed by 2023
2029
Program Completion
All 107 lifeboats upgraded, fleet operational through 2047
2024
Contract Extension
Option exercised for Order – Years 6-10 authorising up to 72 additional overhauls
Outcomes & Impact
Operational Impact
- Increased vessel speed, reliability and fuel efficiency
- Enhanced performance in extreme sea conditions
- Improved crew safety, comfort and mission endurance
Industrial Economic Impact
- Dual-coast refit capability established in Connecticut and Washington
- 200+ American jobs supported across production and supply chains
- Strengthened domestic maritime sustainment capability
Strategic Alignment
- Enables continued Coast Guard mission readiness through 2047
- Provides a cost-effective alternative to full fleet replacement
- Aligns with U.S. priorities for industrial capability
Community & Workforce
- Birdon’s U.S. workforce underpins delivery of the MLB program, with skilled trades and engineering roles supported through apprenticeship pathways and training initiatives. Partnerships with local training providers, veterans’ programs and community organisations strengthen workforce capability and regional economies.
Testimonial
“The unilateral contract modification speaks to the Coast Guard’s confidence in Birdon’s abilities as a major contractor.”
Patrick Kinser
Patrick Kinser, MLB Program Manager
Capabilities in Action
- Full lifecycle vessel sustainment and refit at scale
- Structural, mechanical and systems overhaul of maritime assets
- Integration of propulsion, control and safety systems
- Delivery of dual-coast production and sustainment programs
- Compliance with U.S. Coast Guard performance and safety standards
- Execution of large-scale, multi-year defence sustainment contracts
