Supporting complex naval manufacturing through integrated facility design
At a glance
This case study outlines how we supported Civmec to deliver a secure, large‑scale ship fabrication facility at the Australian Marine Complex in Henderson, Western Australia. It highlights our multidisciplinary design approach, use of digital engineering and innovative construction methods to integrate complex manufacturing, storage and office functions within a single facility for Australia’s defence and advanced manufacturing sector.
The challenge
Australia’s naval shipbuilding program requires facilities that can support the assembly of increasingly complex vessels while meeting strict security, safety and operational requirements. At the Australian Marine Complex in Henderson, Western Australia, Civmec identified the need for a new ship fabrication facility that could bring multiple functions together in a single, highly coordinated environment.
The facility needed to accommodate large‑scale ship assembly, modularisation, surface treatment and office accommodation, while supporting large and heavy component movements and maintaining compliance with Defence security protocols.
A feature of the building is the large number of over head travelling cranes, ranging from 5 tonne SWL up to 100 tonnes. The building structure had to be designed for tandem crane lifts, and to minimise building deflections to meet stringent Australian Standard deflection limits.
Civmec required a facility capable of supporting current naval vessel procurement programs while remaining adaptable for future manufacturing demands. The challenge lay in integrating diverse operational requirements within a constrained site, without compromising efficiency, safety or security.
Key considerations included:
- Managing large and heavy modular components and large vessel sections.
- Coordinating multiple specialist functions within a single facility.
- Meeting Defence security and access control requirements.
- Facilitating rapid workforce movement from carparks into the facility, utilising escalators.
- Supporting efficient workflows across fabrication, treatment and administration areas.
- Delivering the project within a complex construction and staging environment.
Our response
We delivered multidisciplinary design and engineering services for the ship fabrication facility, working closely with Civmec to align the design with operational priorities.
Our work included the integrated design of a large‑scale assembly hall, high‑ and low‑bay storage areas, surface treatment zones and multi‑storey office accommodation. We also designed specialised pavements and laydown areas to support heavy modular components and vehicle movements across the site.
To support coordination across disciplines, we applied digital engineering tools, using Building Information Modelling to enable collaboration, identify clashes early and improve constructability. Security and access control measures were incorporated in line with Defence protocols, while sustainability considerations informed the selection of energy‑efficient systems and an adaptable office fit‑out.
We also supported a novel construction approach for the facility’s “top hat” roof section. This 140‑metre by 40‑metre steel‑framed wall and roof structure was pre‑assembled at ground level, complete with cladding, cabling and crane runway beams, before being lifted 36 metres into position using synchronised jacking. This approach significantly reduced installation time and construction risk.
The impact
Our integrated approach delivered clear operational and delivery benefits for Civmec, including:
- A facility layout that supports efficient workflows across fabrication, treatment and administration.
- Improved safety and coordination through early design integration and digital modelling.
- Infrastructure capable of accommodating large and heavy modules and large vessel sections.
- Compliance with Defence security requirements.
- Flexibility to support future manufacturing and tenant needs.
The completed facility strengthens Civmec’s position within Australia’s naval shipbuilding and advanced manufacturing sectors. The assembly hall supports work on major naval programs, including Offshore Patrol Vessels, while providing capacity for future projects.
By combining multidisciplinary design, digital engineering and innovative construction techniques, we helped deliver a secure, high‑capacity facility that supports efficient operations and long‑term adaptability. The project demonstrates how integrated design can respond to complex industrial requirements within a highly regulated environment.