advanced seaframes for littoral security - … · 2014-11-26 · advanced ship building (asb)...

ADVANCED SEAFRAMES FOR LITTORAL SECURITY

austal-final-1.ps 15/12/09 9:52 am

USS Independence is thefirst of a new generation

of aluminium trimaranLittoral Combat Ship


Navies have often been regarded as among the mostconservative of customers, inherently wary of radicalinnovation in naval architecture and ship design. This

stereotype is not without foundation or reason: first, themarine environment is harsh and unforgiving, and every majorwarship represents a significant capital investment designedto have a service lifetime spanning between two and threedecades; second, navies have by and large pursued an incre-mental approach so as not to inad-vertently cast away the hard-wonlessons of operational experienceaccrued through both peacetimeand conflict.

Yet paradoxically, this slow andevolutionary natural order of warshipdevelopment has been punctuatedat key junctures by the bold adoptionof innovative ship design, marineengineering and/or system architec-ture approaches that depart radicallyfrom conventional wisdom. Theseparadigm shifts generally occurwhen technological breakthroughs and operational impera-tives coalesce to create the conditions for fresh thinking,novel concepts and new enterprise solutions.

So it is perhaps no coincidence that the emergence ofAustralia-based aluminium shipbuilder Austal as a growingforce in the defence market has come at a time when manynavies are radically reappraising the capabilities and charac-teristics required of their future fleets. No where is that moreapparent than in the United States, where the huge potentialof advanced aluminium seaframes is being very firmlygrasped for both littoral warfighting and intra-theatre logisticsmissions.

From humble origins in 1988, Austal has set out to differen-tiate itself from ‘industrial-age’ shipbuilders, and in doing sosought to challenge the conventions and break the moulds solong associated with traditional practice. This is evidenced byits advocacy of marine aluminium alloy as a material ofchoice; a willingness to embrace the hydrodynamic, poweringand layout benefits afforded by advanced high-speed multi-hull forms; an assembly-line production philosophy that owesmore to modern aerostructures manufacture than its does to

classic shipbuilding practice; and a customer-focused deliv-ery culture that endures well beyond vessel acceptance.

It was these tenets that initially brought the company suc-cess in the commercial arena. As John Rothwell, Austal’sfounder and chairman, reflects: “Our original vision was tobuild medium-size fast catamaran passenger ferries, with afirm focus on the Asian market. We honed our skills in thissector, putting particular emphasis on production facilitiesand manufacture efficiencies to enable us to offer tailoreddesigns at affordable prices.”

These same principles were later translated to meet theneeds of customers in the defence and security sector. ”Thecompany saw a need in the late 1990s to diversify the prod-uct portfolio as the ferry market softened,” says Rothwell,“We identified opportunities in the defence and paramilitarysector, and in 1998 achieved a first success with an order foreight patrol boats for the Australian Customs Service.”

Fast forward to the present day. From its small beginnings,Austal has progressively grown through a combination ofselected acquisitions, advanced design development, lever-age from the commercial sector, far-sighted investment innew plant, process and information technology, and a strat-egy of product and market diversification .

As a result, the company’s production resource nowencompasses three facilities located close to its headquartersin Henderson, Western Australia, a vessel production/refityard in Tasmania specialising in vessels up to 60 metres, andAustal USA’s new state-of-the-art ship construction andassembly operation in Mobile, Alabama. Equally important, it

has built up a strong multi-discipli-nary team of almost 200 naval archi-tects, engineers and designers in-house, giving the company a com-plete capability for the design ofadvanced aluminium vessels while atthe same time ensuring hands-onconstruction oversight, and reduceddesign and construction integrationrisk.

The past 14 years have seen thecompany continue to build on itsearly successes. On the commercialside, it has become a market leader

in the design and construction of a new genre of fast multi-hull ROPAX ferries that have revolutionised the economics ofpoint-to-point sea freighting. This has included the pioneering127 m vehicle/passenger ferry Benchijigua Express, thelargest trimaran vessel in commercial service anywhere in theworld.

In parallel, Austal has carved a niche in the defence sector.As well as establishing itself as a leading supplier of flexiblebut affordable fast patrol craft to the Royal Australian Navyand other local and international government agencies, it hasmore recently achieved notable success in applying its inno-vative aluminium multi-hull design and construction expertiseto meet the needs of the US military.

According to Rothwell, it was around the turn of the centurythat the US armed services first began to appreciate thepotential of commercial high speed vessel technology for mil-itary purpose. “There was an awakening of interest in howfast ships could serve as intra-theatre sealift assets, andshortly afterwards, the US Marine Corps chartered the 101 mWestPac Express, at that stage the largest of Austal’s AutoExpress series of vehicle-passenger ferries, to serve as a high

3

THINKING WITHOUT BARRIERS

Austal is re-writing the rule book in the

design and construction of vessels for

military and security applications

Austal’s Henderson facility

ADVERTISING SUPPLEMENT


speed theatre logistics vessel supporting the Third MarineExpeditionary Force in Okinawa.”

Encouraged by this burgeoning interest in theatre sealift,later to become a joint service Program of Record, Austaltook a strategic decision to establish a manufacturing foot-print in the United States. This was achieved through a jointventure, established in 1999, which saw a brand new facilitybuilt on Pinto Island, Mobile, initially to build commercial craft.Austal USA went on to take full ownership in 2006.

While the US services began to develop a requirement for anew class of Joint High Speed Vessel (JHSV), another USopportunity presented itself in the shape of the LittoralCombat Ship (LCS) programme. “We were able to bring theUS Navy across to visit Benchijigua Express and convincethem of the advantages offered by a trimaran,” says Rothwell.“Our design was subsequently downselected as one of twoLCS seaframes to go into build.”

Further success followed in 2008 when Austal USA, by nowfully accredited as a secure site, was selected to deliver theJHSV programme to meet the combined needs of the USArmy and US Navy. An initial requirement exists to build 10vessels using a commercially-derived catamaran design, butas Rothwell points out, the final number “could be more thandouble this figure.”

So what are the factors that have shaped this success? Forone thing, Austal has honed a design resource unrivalled in itsunderstanding of high performance aluminium ships, offeringa wealth of expertise and a proven ability to engineer cus-tomised solutions to meet specific user requirements. In par-allel, it has maintained a vibrant research and developmentprogramme that has matured innovation in hydrodynamics,structures, power and propulsion and ride control.

Next, it has succeeded in migrating commercial off-the-shelf (COTS) design solutions into the military environment bymethodically engineering proven aluminium fast ship tech-nologies into high performance designs – without compro-mise to operability, safety or survivability. This is borne out bya track record of 69 vessels delivered, in build or on order, to

12 armed forces and law enforcement agencies worldwide. The company has also invested in the in-house develop-

ment of key system technologies interwoven into itsadvanced high speed multi-hull designs. For example,Austal’s MarineLink ship monitoring and control networkallows for comprehensive real-time monitoring and manage-ment of machinery and systems ship-wide from the bridge. Inaddition, MarineLink produces trend information to supportvessel operation and platform diagnostics.

Similarly, Austal has continued to cultivate its own expertisein ride control systems. This capability includes sophisticatedcomputer-based modeling tools to predict and evaluate sea-keeping performance, and the development, manufactureand integration of software-controlled motion control systemsto reduce ship motions at speed and in higher sea states.

Production efficiency is another major contributor toAustal’s performance and competitiveness. The company’smanufacturing facilities have been optimized to streamlineworkflow and maximise productivity, with a particular focuson large scale modular pre-outfit.

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The Royal Australian Navy operates 14 Austal-built Armidale class patrol craft

Offloading from WestPac Express


Intrinsic to this continuing drive for efficiency is theAdvanced Ship Building (ASB) programme, a continuousimprovement and change management initiative woven intothe fabric of Austal’s business. ASB is all about improving effi-ciency and increasing output quality, achieved through theadoption of new operating processes and manufacturingtechniques, integrated project planning, coordinated logis-tics, greater accuracy in piece part manufacture, and rigorousconfiguration control.

Further benefits are anticipated from the roll-out of a wasteelimination programme based on ‘lean’ manufacturing princi-ples. This is already delivering significant gains in productivityalongside improvements in quality and shopfloor safety.

The other special ingredient, Rothwell believes, is a cultureand mindset that challenges conformity and puts the customerfirst. “There is very much a ‘can do’ approach,” he says,adding “Our business has been all about giving clients,whether commercial or military, solutions that were simplyunattainable using traditional approaches. We’ve done thatthrough innovative engineering and world-class manufacturing.

“Austal is leading in an industry where no one else hasbeen, so we can’t copy. We’re thinking without barriers.”

Looking to the future, the corporate business plan antici-pates a continued intake of both commercial and defencework, with the latter expected to account for slightly morethan half of group turnover in the longer term. Austal USA willfocus its operations on the military market, with high hopesthat LCS and JHSV production will be buoyed by interna-tional orders through US government Foreign Military Sales.

Outside of the United States, Austal is examining options toestablish a specialist military production facility operatingseparate to its existing commercial build facilities. This wouldharness the production efficiencies of the company’s alu-

minium shipbuilding operation, while at the same time pro-viding a secure site environment aligned to the more complexintegration, certification and security requirements of navalcustomers.

What’s more, alongside its established range of patrol andauxiliary boat designs, Austal is introducing a new Multi-RoleVessel concept that combines the efficiencies and layoutadvantages of the trimaran hullform with a system of modu-lar mission payloads. The result is an agile yet affordable lit-toral combatant geared to the needs of the 21st century navy.

Another line of development is through-life service support.Austal has taken responsibility as the ship manager forWestPac Express, including planned maintenance manage-ment, and is also providing support to the Royal AustralianNavy’s Armidale class from an operation in Darwin operation.And its five-year support package for new patrol boats builtfor Trinidad and Tobago is likely to be a portend for things tocome.

There is also an acknowledgement that Austal should adaptto a global marketplace where customers increasingly aspireto in-country manufacture. Rothwell points out that the com-pany “is open to exploring options for technology transfer,whether through the direct licensing of designs or the cre-ation of joint ventures”.

Austal remains a young company, celebrating the 21stanniversary of its formation in 2009, yet its track record ofsuccess, first in the commercial market and now repeated inthe defence sector, suggests it has more than come of age. Ina short time, it has effectively torn up the conventions of mili-tary shipbuilding by applying commercial business processesand COTS technology solutions carefully tailored to meet thecapability requirements of defence customers. Above all,Austal has shown that things can be done differently.


Extensive in-service experi-ence with aluminium hulls,together with a continuingprogramme of research, devel-opment and technologydemonstration, has givenAustal the confidence to arguea persuasive case for usingaluminium material in navalhull structures. Indeed, as mis-conceptions and prejudicesare overcome, an increasingnumber of navies have recog-nised the benefits of reducedstructural weight, better fueleconomy and enhanced corro-sion resistance that aluminiumconfers.

Aluminium is approximatelyone third the weight of steel,offering a far lower lightshipdisplacement and thereforeincreasing speed and fuel effi-ciency without sacrificingstructural strength. It is alsoan extremely robust materialfor marine operation; in thecase of a high shock loading,the high ductility of aluminiumensures that significant paneldeformation can be toleratedbefore structural failure.

The corrosion resistance ofmarine grade aluminium alloysensures that protective coat-ings are not required on allhull surfaces. A protective alu-minium oxide layer that forms

on the material surfaceensures that bilges, tanks,voids and other internalspaces do not require the levelof maintenance, and coatingthat steel hulls do

Aluminium and steel arealike in that both materials arenon-combustible and do notburn. The key behavioural dif-ference is that aluminiumalloys lose strength at a lowertemperature than steel (degra-dation starting at tempera-tures between 150 and 180degrees C).

Austal recognises that alu-minium’s increased suscepti-bility to fire damage demandsincreased structural fire pro-tection in those areas of firerisk, this being deliveredthrough a ceramic fibre woolmateriel and the installation ofactive fire suppression sys-tems. However, the substantialdifference in structural weightmore than offsets the weightof additional fire protectionmeasures.

The company also points outthat aluminium conducts heatmore effectively than mildsteel. This thermal conductivityassists in the dissipation ofheat during a fire and allowsrapid boundary cooling ofexposed structures.

Austal’s highly skilled workforce deliversoutstanding efficiency and quality


Matching finite budgets to an ever-widening range ofmaritime security and warfare enabling tasks is aproblem that continues to challenge navies world-

wide. Many forces are discovering that the one-to-onereplacement of existing minor war vessel types – patrol ves-sels, mine countermeasures craft and survey ships – is bothunaffordable (in terms of acquisition cost) and undesirable(given the training, logistics, organisation and manning over-heads that aggregate through-life from a series of unique,niche and largely bespoke platforms).

As a consequence, there is significant evidence of a shift inthinking towards the concept of a modular and reconfig-urable minor warship design that confers an ability to be re-configured to satisfy a range of different roles according tothe specific mission payload embarked. Reconfigurability isincreasingly attractive to navies that want to be able toadjust the balance of roles and missions performed byindividual units warships in a flotilla as tasking prioritiesevolve over time. This offers improved role (versus hull num-ber) flexibility through life.

This trend is reflected by a number of emergent plat-form/capability requirements. For example, Australia’sProject SEA 1180, as a core component of the RoyalAustralian Navy’s Force 2030 vision, plans to replace legacypatrol boat, mine countermeasures (MCM), hydrographicand oceanographic forces with a single modular multiroleclass of Offshore Combatant Vessels.

In articulating this approach, the Defence Capability Plan2009 describes the rationalisation of the small ship fleet as“an opportunity to leveragethe advantages of platformand systems commonality asfar as it can be implementedto fulfil a range of maritimemissions”. It adds that itsplanned approach “isintended to exploit the advan-tages of using either the samevessel or a family of vessels toconduct offshore security,mine countermeasure andhydrographic roles,” notingthat, where possible, “thisvessel or family of vessels willemploy modular concepts thatenable each to be employedin multiple roles to meet theneeds of particular operationsor strategic circumstances”.

Austal has already started thinking along similar lines.Drawing on its in-house design expertise, together withfeedback garnered from the RAN and a host of other inter-national navies, it has produced an innovative Multi RoleVessel (MRV) design that succeeds in melding the powering,seakeeping and layout advantages endowed by an alu-minum trimaran seaframe with the adaptability afforded by amodular payload system. The result is a supremely agile andcost effective open architecture platform that transcends tra-ditional ship typologies to deliver superior operational flexi-bility.

Having already brought large high-speed trimaran technol-ogy into the military marketplace in the shape of the LCS,Austal has continued to evolve and finesse the basic designin order to further optimise performance, ride control, fuel

efficiency and payload. These improvements are embodiedin the next-generation AutoExpress 102 vehicle/passengerferry, construction of which completes at the company’sHenderson yard in early 2010.

The MRV has been designed to capitalise on this pedigree,providing users with a versatile yet cost effective littoralseaframe that exploits the inherent advantages of the tri-maran hullform to offer significant advantages over a similar-

size monohull. These includeimproved hydrodynamic per-formance and greater propul-sion efficiency, increasedinternal volume for a flexiblemission/logistics deck, and alarge and optimally sited flightdeck and hangar for helicop-ter and/or unmanned air vehi-cle operations and support.Austal’s concept combinesthese features with a corecombat system -- scaled forsituational awareness andself-defence – and a shipservice infrastructure thatsupports interfaces to a widerange of mission payloadssuited to specific naval, mar-itime security, theatre logis-

tics, law enforcement, and humanitarian roles. The result is an 80 m platform that seeks to redefine the

term ‘multi-mission’ by offering the prospect of true ‘plugand play’ operation. This in turn offers end users a highlyadaptable asset that can be rapidly reconfigured to delivercapability across the full spectrum of operations.

A stand-out feature of the design is the mission bay areathat provides a large storage and/or working area. Payloadscan be moved internally by means of a gantry crane, ormoved out to a V-notch in the transom for launch.

Vehicular access is via an aft stern ramp, while an aft craneallows for cargo handling and the launch and recovery ofsmall craft and unmanned surface vehicles. Austal is contin-uing to investigate novel motion-compensated capturemechanisms that enable recovery operations to be safely


VERSATILITYWITHOUT

COMPROMISEAustal’s Multi Role Vessel offers a new

and innovative approach to meeting a

raft of maritime security needs

Aft view of the MRV


and efficiently performed in higher sea states. The hangar and flight deck are sized for an MRH-90 type

helicopter. The inherent stability of the trimaran form,together with the positioning of the flight deck nearer to thecenter of pitch, significantly reduces motions so as toexpand helicopter operating limits in rough weather.

Austal believes the MRV offers an ideal platform from whichto perform EEZ surveillance and maritime security opera-tions, championing both the efficiency and seakindliness ofthe MRV seaframe. While the design is capable of sprintspeeds approaching 30 kt, most operations are likely to beundertaken at an economical cruise speed between 12 ktand 15 kt, a powering regime where the hydrodynamic effi-ciencies of the trimaran form yield significant savings in fuelconsumption compared to a similar monohull. Furthermore,

the low motion characteristics of the platform are ideal for anasset that may be required to loiter on station for extendedperiods.

Of course, the benefits of improved seakeeping andseakindliness are not just confined to crew comfort. Shipevolutions involving a ship/sea and/or ship/air interfacerequire low motions to endow acceptable safety and operat-ing limits, while the MRV’s multi-hull form naturally providesa sheltered area for the launch and recovery of boats orunmanned vehicles. These self same attributes lend them-selves to the operation of a next generation of offboard MCMand hydrographic survey systems, embarked in the form ofcontainerised and portable modules, that will rely on thedeployment of long-range autonomous vehicles from ‘standoff’ distances.

As for sealift and intra-theatre logistics, the MRV offersseating area to accommodate an embarked military forceequivalent to an entire battalion, with space in the missiondeck for vehicles, cargo and containers. The craft’s shallowdraft characteristics (less than 3 m) and excellent close quar-ters manoeuvrability enable it to access austere and con-fined port arrangements.

This intrinsic payload flexibility and ability to operate inwaters close inshore further lends itself to humanitarian reliefmissions. In this case the mission deck could accommodatecontainerised medical facilities, relief supplies, mobile work-shops and engineering vehicles.

While the MRV will be built to commercial classificationsociety standards, measures will be implemented to providesome degree of ‘hardening’ for mission systems. Theseinclude shock-tolerant cabinets for electronics hardware,and the selective application of lightweight armour aroundcritical operational spaces.

Combining innovative design with proven, state of the prac-tice technology, Austal’s MRV concept offers navies andcoast guard’s a new route by which to deliver a wide varietyof maritime security and enabling roles from a single platform.


While Austal does not carrythe significant overheadsassociated with the mainte-nance of an in-house combatsystem engineering group, ithas steadily built up a profi-ciency in the integration ofaffordable sensor and weaponsuites matched to constabu-lary and self-defence require-ments. At the same time, thecompany is increasingly work-ing with third party combatsystem suppliers to integratetheir combat management,sensor and weapon systemswithin its aluminiumseaframes.

The MRV provides an idealexample. Austal has defined acore combat suite that deliversa level of situational aware-ness and tactical control com-mensurate with the maritimesecurity and littoral surveil-lance missions that the vessel

is ideally suited to. This wouldtypically include a compactopen architecture combatmanagement system, a tacticalair/surface surveillance radar,a radar/electro-optical weaponcontrol infrared surveillancesystem, electronic supportmeasures and communicationsintercept/direction finding.

Effectors would also be tai-lored for the littoral securitymission. A baseline fit couldinclude a 57 mm dual-purposemedium-calibre gun and anumber of small-calibreweapons for policing opera-tions and close-in protection.Navies looking for a more sub-stantial armament could addi-tionally fit a lightweight sur-face-to-surface guidedweapons and/or a very shortrange air defence system,together with soft-killchaff/infrared decoy launchers.

The MRV has been specifically designed tooffer maximum versatility in service


Nation states today find themselves faced withincreased responsibilities to monitor and police theactivities within inshore zones, along their coastlines

and beyond into the EEZ so as to protect maritime borders,safeguard offshore installations, resources and ecologies,deter criminal elements and counter threats to national secu-rity. This requires a flexible, responsive and cost-effectiveseaborne patrol capability to ensure the integrity of territorialwaters, and deter or apprehend those undertaking activitiesoutside the law, ranging from illegal fishing, environmentaltransgressions and narcotics smuggling to human traffick-ing, piracy and maritime terrorism.

At the same time, there is a continued requirement forrobust, adaptable and sea-kindly vessels able to demon-strate sustained presence, and contribute to the mainte-nance of good order at sea, maritime safety, and search andrescue.

Responding to these varied operational demands, Austalhas over the last decade evolved a line of high performancealuminium patrol boat and auxiliary vessel designs that canbe individually scaled and tailored to meet the specific needsof the end user, be it a navy, defence force, coast guard orother paramilitary agency. Characterised by attributes ofspeed, manoeuvrability, shallow draft, low-manning andreduced maintenance, they enjoy the benefits of proven V-hull aluminium platforms that combine economical perform-ance with superior seakeeping. Furthermore, the inherentflexibility of each design allows customers a wide choice inthe selection of equipment and vendors to suit specific oper-ational and/or local supply chain and support requirements.

Austal’s first success in this market came in 1998 when itwas awarded a contract to build eight 38 m ‘Bay’ classpatrol boats for the Australian Customs and BorderProtection Service. Since then it has gone on to secureorders from eight military/law enforcement customers for 55patrol vessels varying between 16 m and 56 m in length. Thepedigree of this ‘back catalogue’ includes 10 patrol vesselsfor the government of Yemen and the Royal AustralianNavy’s 14 Armidale class patrol boats, the latter procured tomeet the requirements of Project SEA 1444.

What marked out the acquisition strategy for Project SEA1444 was the Department of Defence’s adoption of a per-formance-based requirement. Rather than specify thedetailed characteristics, performance and number of ves-sels, Defence instead sought to define a patrol boat capabil-ity based on operational availability, and let industry decideon the number of platforms and associated support strategy

required to most cost effectively deliver this output.The Armidale build programme, contracted in December

2003 as part of a 15-year package that also incorporatesthrough-life maintenance and support, represented a break-through for Austal given the pace of delivery, the range andseakeeping performance demanded of the vessel, and therequirement to integrate a compact but highly capableweapon, sensor and communication suite. Today operatingfrom bases in Cairns, Darwin and Dampier, the Armidaleclass vessels are making a significant contribution topatrolling Australia’s vast EEZ.

As well as earning praise from the RAN for its reliability,habitability and seakindliness, the Armidale design alsoserves as a reference point for the advantages of aluminiumconstruction. Its use has resulted in an annual fuel saving ofmore than 20% compared to a similar steel design, equatingto a saving of around 2.1 million litres of fuel per year for the14-strong fleet. This, coupled with reduced maintenanceoverheads, is generating significant life cycle cost savings

More recent patrol craft orders have reaffirmed Austal’sability to utilise its high productivity design and manufactur-ing capability to deliver customised products against thetightest programme schedules. In April 2008, following acompetitive tender process, the Republic of Trinidad andTobago awarded the company a contract to construct six 30m APB 30 fast patrol boats for service with the Trinidad andTobago Coast Guard (TTCG), an order which marked thefirst defence sale for Austal in the Caribbean region.

According to Commodore Garnet Best, Director ofTrinidad’s Defence Transformation and IntegrationSecretariat, the technical and commercial proposal put for-ward by Austal won out because it “offered the best overallpackage, which covered the provision of the vessels, train-ing and maintenance”.

These new craft, all delivered by the end of 2009, will sup-port the TTCG in providing sustained surveillance in thecountry’s internal waters, the archipelagic territorial sea andits exclusive economic zone. It is intended that the vesselswill play a major role in ensuring the safety of shipping, aswell as the preservation of the marine environment. They willalso target the illegal trafficking of drugs, contribute to safetyat sea, and perform search and rescue duties.

“Our first impressions of the vessel were excellent,” says


SECURITYIN THE

LITTORALSCustomers worldwide are turning

to Austal for the supply of high

performance patrol craft

Six APB30 vesselshave been delivered toTrinidad and Tobago


Commodore Best, “with theboat maneuvering well andthe speed was right up over40 knots. We are confidentthat the speed of the vesselswill contribute to their effec-tiveness in the interdiction ofillegal drugs.”

Classed to DNV standards,the APB 30 typifies the newgenre of fast patrol vessel forwhich Austal expects asteady demand in the yearsahead. Powered by twin MTU16V 2000 M92 series dieselengines driving Rolls-RoyceKamewa size 56 waterjets, itcan achieve a maximumspeed of 40 knots and a max-imum range of more than1,000 nautical miles.Operating with a crew of 12,each craft is being equippedin service with a 20 mm can-non and three GeneralPurpose Machine Guns.

As part of its full service commitment, the company deliv-ered a comprehensive customer training programme at itsdedicated training facilities in Western Australia ahead ofvessel delivery. The package comprised two parallelstreams: a familiarisation training programme for TTCG deckofficers and ratings; and a maintenance training programmefor engineer officers and ratings. Further training to TTCGpersonnel will follow in Trinidad and Tobago from early 2010.

It should be pointed out that Austal’s responsibilities to theTTCG did not end with vessel handover. Under a separatebut associated contract, the company is providing a five-year comprehensive maintenance and support service incor-porating scheduled planned and preventative maintenancesupport, unscheduled maintenance, management and per-formance of annual surveys and maintenance periods aswell as shore-based engineering support.

Austal’s high quality and price competitiveness have alsocontinued to find favour with law enforcement agencies, withthe Queensland Police Service recently taking delivery ofthree 22 m catamaran vessels designed for extended patrols

in remote tropical areas. Builtby the company’s Tasmanianshipyard, which specializes insmall to medium size vesselconstruction, their clever butcompact design include theability to drive on/drive off arigid inflatable boat on an aftramp.

In February 2009 the ArmedForces of Malta (AFM) reaf-firmed Austal’s competitive-ness in the patrol craft mar-ket by placing an order forfour 21.2 m inshore patrolcraft. This is a milestone con-tract in that it hails a firstbreakthrough for the com-pany in the Europeandefence market. It also high-lights Austal’s ability to meetexacting customer demandsin exceptionally shorttimescales, with just ninemonths between contractsignature and delivery.

The AFM, which has responsibility for security in Malta’s ter-ritorial waters, will employ the four vessels for surveillanceand border protection missions around the island state’scoastline. Each vessel will be equipped with a 12.7mm heavymachine gun forward and two 7.62mm light machine guns onthe aft flybridge deck.

Operated by a crew of eight, the craft will offer muchimproved crew comfort and safety. Twin MAN D2842 LE410diesels, diving fixed pitch propellers via ZF gearboxes,deliver a maximum speed of over 26 knots.

Adding to the design’s versatility is a bilge manifold locatedabove the main aft deck, which can perform salvage pump-ing of another vessel if needed. A stern launching rampallows the safe deployment and retrieval of a rigid inflatableboat and dive operations are also supported via low-to-the-water platforms located aft. The vessels also boast fire fight-ing capability via a fire monitor on the aft flybridge deck.

Sea trials of the first two Maltese inshore patrol craft beganin early October 2009. Delivery of all four vessels has beencompleted on schedule.

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With many customers nowplacing an increased emphasison asset availability and morecost-effective capability man-agement through-life, Austal isgrowing its capability todeliver comprehensive full-service logistic support pack-ages across its range ofdefence and security plat-forms.

Drawing on the extensiveexperience of its global servicenetwork, the company is nowable to offer tailored through-life support packages toensure optimised vessel sup-portability and reduced lifecy-cle costs. These servicesinclude maintenance planning,logistic support, operator and

maintainer training, unpro-grammed maintenance andrepairs, technical consultancy,safety management, post-design services, and assis-tance with dry docking andsurveys.

Austal’s service is inherentlyflexible so that support pack-ages can be customised to suitthe unique needs of individualoperators, ensuring they areprovided with support that iseffective, efficient, and coher-ent with capability, availabilityand affordability requirements.This includes the provision ofinnovative and locally sustain-able solutions that make bestuse of in-country infrastructureand supply networks.

Four IPCs have beenbuilt for Malta

Kuwait operates three Austal-built 22m patrol boats



The futuristic shape of USS Independence (LCS-2), thefirst Austal-designed and -built Littoral Combat Ship(LCS) for the US Navy, is physical testament to the fact

that it is in the United States where Austal’s advancedseaframe technology has made the biggest impact. Equally,as the world’s largest aluminium warship, its radical form pro-vides a powerful demonstration of the confidence placed inthe company by the world’s most powerful maritime force.

Independence is a truly transformational vessel, offering themultiple benefits of shallow draft, high speed, superiorseakeeping, optimised aviation facilities, a modular openarchitecture mission system, and a large and reconfigurableinternal mission deck. And all this it is enabled by trimaranhullform technology originally conceived by Austal forcommercial service.

It was back in early 2000 that the company launched aprogramme of research and development with the objective todevelop a new hull design that would deliver high speeds inrough seas while at the same time offering the seakeepingperformance required to ensure the highest standards ofpassenger comfort. This work spawned a revolutionary 127 mtrimaran design that, with the delivery of the ferry BenchijiguaExpress to Fred. Olsen, S.A. in April 2005, opened a new erain fast sea transportation.

Austal quickly recognised that the same aluminium trimarantechnology offered huge potential in the military environment,affording the inherent advantages of large internal volume,flexible layout, shallow draft, more efficient powering and goodmanoeuvrability. Moreover, it gave the ability to carry asubstantial payload at high speeds in a seaway without theloss in speed typically experienced with other hullforms.

What’s more, tank testing and simulation has demonstratedthat, in a wide range of wave conditions, the trimaran hullformoffers improved seakeeping thanks to its ability to provide lowtransverse and vertical accelerations. This results in superioraviation and watercraft operational capability, and ensures thatcrew are less susceptible to fatigue or seasickness from shipmotions, an even moreimportant consideration ascomplements are downsized.

The US Navy’s LCSprogramme has provided thefirst opportunity for Austal tobring its trimaran technologyforward into the front-line.Conceived specifically tooperate and fight in shallowwater environments close toshore, the LCS will embarkinterchangeable missionpackages to tackle threats asdiverse as mines,submarines and fast attackcraft. Furthermore, it will offerthe capability to deployindependently to distantoperating theatres andremain on station forextended periods. A class ofup to 55 ships is planned.

What became apparent tothe US Navy at the outset ofthe LCS acquisition effortwas that requirements for

high sprint speed and outstanding manoeuvrability, withoutcomprise to efficiency, range, seakeeping, shallow draft andhigh payload capacity, demanded a platform solution welloutside the bounds of traditional steel warship design. So theservice looked instead at alternative ‘game-changing’approaches that emphasized the cost-effective pull-through ofproven high speed vessel technologies accessible ‘off theshelf’ from the international marketplace.

Austal’s pedigree shone through. Having participated inconcept-level Focused Mission High Speed Ship studies, andwith Benchijigua Express offering a design benchmark, thecompany’s advanced aluminium trimaran was in 2004downselected as one of two LCS seaframes. The keel of thefirst unit, Independence, was symbolically laid down at AustalUSA’s yard in January 2006.

The LCS trimaran seaframe is truly pushing the frontiers ofnaval vessel design. Theslender center hull and twosmaller side hulls gives thevessel the operationalcharacteristics of a largerdisplacement craft, providinggreater stability in rough seasand operational conditions.

Furthermore, the aluminiumstructure – certified by theAmerican Bureau of Shippingfor a 30-year service lifebased on a detailed spectralfatigue analysis – provides acapacious mission bay areaoffering superior role andmission flexibility, rapidreconfigurability, improveddamage protection and amplemargins for future growth.This translates into aninherently versatile combatantthat adopts true openarchitecture principles so asto de-couple the platform andcore mission system from theinterchangeable modular


BUILDINGFUTUREFLEETS

Austal USA is constructing a new wave

of advanced aluminium seaframes

to create a new-age navy

LCS-2 Independence


payloads it embarks according to its specified role.Above the mission bay is the largest flight deck on any US

Navy surface combatant. Capable of conducting dual H-60helicopter operations and accommodating the CH-53 – theservice’s largest rotary-wing aircraft – this elevated aviationarea benefits from reduced sea spray ingress as well as theinherently superior seakeeping performance of the trimaran soas to significantly expand the helicopter operating envelope inhigher sea states.

A power-dense Combined Diesel and Gas Turbine (CODAG)main propulsion system comprises two MTU 8000 seriesdiesel engines and two GE LM2500 gas turbines driving fourWärtsilä axial flow waterjets. This CODAG arrangementcombines delivers an outstanding 45 knot sprint speed at fullpower, and extended range and fuel efficiency in aneconomical diesel-only cruising regime. What’s more, thealuminium trimaran has a total installed power of just 62 MWcompared to 84 MW on the smaller competing steel monohullseaframe.

Independence was launched on 28 April 2008 and, followingextensive alongside testing of propulsion, communications,navigation and core mission systems, began first sea trials inearly July 2009. A second and final series of builder’s trialswas successfully concluded on 18 October.

Construction of a first follow-on vessel, to be named USSCoronado, began in late 2009. Delivery is planned for 2012.

Alongside the LCS programme, the operational advantagesoffered by Austal’s advanced high-speed seaframetechnology have latterly been recognised by a joint-serviceendeavour that will fashion a new fleet of theatre logistics craftfor the US Army and Navy. The Joint High Speed Vessel(JHSV) programme is intended to radically change the intra-theatre transport of medium-sized cargo payloads overwater,capitalising on fast ferry seaframe technologies so as tocut costs, accelerate logistics delivery, and reduce reliance onshore-based infrastructure.

The result is a non-combatant vessel offering similar

capabilities to a high-speed commercial ferry - and henceadopting commercial international survivability standards – butmodified to incorporate a flight deck and aviation facilities,vehicle deck offload ramp and appropriate firefighting, C4I andforce protection facilities. An initial buy of 10 JHSVs has beenapproved – split equally between the Army and Navy – withprospects for follow-on orders.

Following a competitive preliminary design phase, Austalwas in November 2008 awarded a US$185 million contract bythe US Naval Sea Systems Command for the detailed designand build of the lead JHSV, with options for the build of up tonine additional ships, plus associated shore-based spares.The potential value of the 10-ship programme is estimated atover US$1.6 billion.

Austal’s unique experience of large aluminium multi-hullplatforms enabled it to tailor a design that best met the JHSVperformance and cost requirements. Given the weightingsattached to key performance criteria, it developed a 103 mcatamaran that leveraged a round-bilge, bulbous bowhullform refined from that already well proven by WestPacExpress, and the same MTU 8000 diesel prime movers usedin both the LCS and numerous commercial vesselprogrammes.

The result is an affordable and low-risk platform, designed toABS High Speed Naval Craft code, which meets the JHSVobjective mission and aviation requirements with structuraland operational reliability. Stand-out features include the abilityto transport 700 tons of payload over 1,200 nm at an averagespeed of 35 knots, 3,500 nm range, a 2,000 m2 mission deckfor vehicles and cargo, organic cargo handling facilities, andthe capability to operate a CH-53 helicopter from a flight deckaft. Furthermore, alongside accommodation for the 41 crew,the JHSV will be able to berth up to 150 in maximum loadconditions, with additional airline-style seating for a force of312 troops.

Austal's principal partner is General Dynamics AdvancedInformation Systems, which, as Platform Systems EngineeringAgent, will design, integrate and test the JHSV's electronicsystems, including an open architecture computinginfrastructure, internal and external communications,electronic navigation and self-defence systems. It is alsotaking responsibility for the flight deck arrangements, includinglighting and visual landing aids.

Following the successful conclusion of ProductionReadiness Review, Austal USA began the build of Fortitude,the first JHSV, towards the end of 2009 with deliveryscheduled for 2011. Options for long lead time materials forthe next two vessels, Vigilant and Spearhead, have alreadybeen exercised.

11

Austal USA’s facility in Mobileis currently undergoing a majorexpansion programme which,on completion, will double theyard’s shipbuilding capacity.This latest investment in astate-of-the-art ModularManufacturing Facility (MMF)marks the culmination of adecade-long strategy that hasseen Austal carefully nurturethe development of both pro-duction areas and skilledlabour so as to confidentlydeliver a new generation ofadvanced aluminium seaframesto the US government.

Since its establishment in1999, the Mobile site has grad-ually built up its expertise inthe construction of aluminiumships, initially for the commer-cial market. This began withworkboats and smaller cata-

marans, later stepping up totwo 107 m Hawaii SuperferryROPAX catamaran ferries.Over that same period, theyard has benefitted from asignificant and sustained pro-gramme of facilities invest-ment.

The latest development atthe Mobile yard is the con-struction of the new 70,000m2

MMF on a 100 acre lot adja-cent to the existing site. Phase1 was completed in 2009, withPhase 2 to complete in 2011.The new facility will improvethe efficiency of Austal USA’sproduction processes, and pro-vide the additional manufactur-ing capacity to allow the yardto handle a throughput of upto six large aluminium vessels– such as the LCS or JHSV –per year.

Austal USA in Mobile, Alabama

JHSV brings a new dimension to intra-theatre logistics




Shipyards: Australia and USAEmail: [email protected] Fax:+61 8 9410 2564 Tel: +61 8 9410 1111

W W W. A U S TA L . C O M

A U S T R A L I A ’ S G L O B A L N A V A L P R I M E

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