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Mobile, Ala.
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Austal, an Australia-based company, is the world’s largest manufacturer of aluminum commercial and defense vessels. Gray provided design-build services for the first phase of a 459,899 s.f. modular manufacturing facility (MMF) used to produce the Littoral Combat Ship and the Joint High Speed Vessel for the U.S. Navy in Mobile, Ala. As this project neared completion, Austal turned to Gray for modifications to an existing pre-engineered building on its Mobile campus. In 2011, Gray was selected again to design and build the 393,107 s.f. second phase of Austal’s MMF and a new 108,122 s.f., three-story office complex.

Project Facts

  • Phase One MMF:
    • Facility is the size of about six football fields.
    • One 250-ton crane, five 40-ton cranes. four 20-ton cranes, five 10-ton cranes, six 5-ton cranes
    • Used over 7,200 tons of steel
    • Installed long-span steel plate girders weighing 109 tons and 137 tons
    • Moved 23,000 dump truck loads of dirt
    • Used 31,000 cubic yards of concrete
  • Phase Two MMF:
    • Mirror image of Phase One, doubling existing manufacturing space
    • Aviation-style fabric doors rated for hurricane strength
    • Five three-story office modules, two 125-ton cranes, eight 40-ton cranes, four 20-ton cranes, five 10-ton cranes, seven 5-ton cranes
  • Office Complex:
    • Reconfigurable multi-purpose room with seating for 400
    • Elegant curved glass facade constructed of steel and metal panel walls
    • Numerous high-end finishes including a custom aluminum wall hanging
    • Project received Associated Builders and Contractors, Inc. (ABC) Alabama Excellence in Construction Award

Services Provided by Gray:

  • Programming
  • Architecture
  • Building Systems Analysis and Design
  • Interior Design
  • Building Information Modeling (BIM)
  • Project Visualization
  • Civil Engineering
  • MEP Engineering
  • Process Engineering
  • Structural Engineering
  • Construction Management
  • Equipment Installation