Program Overview
Birdon was contracted to design, manufacture, test, certify and deliver 14 new ferries for Sydney Harbour, carrying full program responsibility from concept design to through to final acceptance.
The fleet comprises of three Emerald Class ferries and ten River Class ferries and one on-demand minicat. Construction was delivered across Birdon’s Port Macquarie yard and partner shipyards in Asia, with final fit out, testing and commissioning completed in Australia.
Quick Facts
- Client
Transport for NSW (TfNSW), in partnership with Transdev Sydney Ferries
- Location
Port Macquarie (Australia) and international partner yards (Asia)
- Lifecycle Stage
Design, Build
- Fleet Composition
3 Emerald Class ferries (F1 Manly route)
10 River Class ferries (replacing SuperCats and HarbourCats)
Objectives
- Deliver a modern, reliable ferry fleet to meet Sydney’s growing commuter demands
- Maintain high levels of Australian Industry Content (AIC)
- Complete the project on an aggressive schedule despite global disruptions
Challenges
- COVID-19 travel restrictions and supply chain disruptions
- Political and public scrutiny over overseas fabrication
- Need for rapid delivery to meet commuter expectations
Birdon’s Approach
- Subcontracted hull design for three ferry variants
- Led systems integration, production engineering and configuration management
- Managed overseas shipyards under Birdon’s quality and procurement systems
- Final fit-out, testing and commissioning completed in Port Macquarie and Newcastle
- Sourced major components including engines, propulsion, interior fit out and electronics in Australia
Outcomes & Impact
The project was delivered on time despite pandemic-related challenges, with all ferries now in service across Sydney Harbour. The program demonstrated Birdon’s ability to manage complex, multi-site international shipbuilding programs while maintaining strong Australian industry participation.
The project also contributed to regional economic outcomes, including the creation of 18 new roles in Port Macquarie to support final fit-out and commissioning activities.
Critical Public Infrastructure Delivery
A multi-site global build program delivered at scale and on time, combining strong Australian industry participation with complex international coordination under challenging market conditions.
Ferries Delivered
A new generation fleet designed, built, and deployed across Sydney Harbour.
Australian Suppliers
Majority of contract value sourced through Australian materials and suppliers.
Regional Jobs Created
New roles established in Port Macquarie supporting final fit-out and commissioning.
Testimonial
“The experience of working with Birdon has been fantastic. Our relationship has been right since inception. We came together and committed to common goals to achieve the build.”
Adam Moore
Engineering Manager, Transdev Sydney Ferries
Capabilities in Action
- Systems integration, production engineering and configuration management across multiple vessel classes
- Management of international shipyards under Birdon quality and procurement systems
- Final fit-out, testing and commissioning delivered in Australia
- High Australian Industry Content across materials, components and labour
- Delivery of a complex, multi-site program under challenging global conditions
