The stem, positioned at the front of the vessel, is a critical structural element that defines the ship’s hydrodynamic shape and brings both sides of the hull together. Formed from molten steel casting, it provides essential strength to the frigate’s forward structure.
The installation followed a ten-day continuous welding effort, requiring precise execution due to the availability of only one casting per ship. The component was fitted onto the foremost steel unit, one of 78 units that will form the completed vessel.
The stem casting was produced in the United Kingdom by Goodwin Steel Castings using a traditional foundry process. Two cast sections were joined to create the final 3,920 kilogram structure before it was transported to Australia for installation.
Lauren Townsend, Head of Operations Management for the Hunter Class Frigate programme, said the activity represented a significant step forward. “We only have one stem casting per ship, so it was vitally important that the team got it right. We’ve been through months of preparation, pulling on all of the different functions, to get us to this point.”
The welding process required the casting to be preheated and maintained at 200°C throughout to meet certification standards set by Lloyd’s Register. Teams worked continuously in 24-hour shifts to maintain the required temperature, completing the process safely in ten days instead of the planned two weeks.
Mick Noy, Fabrication Manager, highlighted the technical complexity of the task. “I’ve been in shipbuilding for nearly 20 years and we’ve never had a casting like this — not at this scale and not with this level of pre-heat. I’ve never seen anything like it. To achieve the required weld quality, we couldn’t let the heat off at any point. So, we went 24/7, day and night shifts, until the job was complete.”
Noy said the achievement reflected coordination across multiple teams beyond production alone. “I’m extremely proud of the team — and that’s not just in the production sense. From the pre-mortem planning session, through manufacturing, engineering and the safety team, everyone pulled together in a short timeframe to make sure we could get this done.”
The operation required additional safety measures due to confined working conditions and sustained high temperatures. Measures included fatigue management, enhanced protective equipment, cooling systems, specialised breathing air and on-site health support.
The successful installation is expected to strengthen capabilities for future ships in the programme. Townsend said, “This milestone puts us in a really strong position for the future vessels. We’ve built skills, experience and confidence — and it’s a model we can lift and shift for other key installs as the build progresses.”
The company said the milestone demonstrates the broader development of Australia’s naval shipbuilding capability. It also reflects efforts to build a skilled workforce able to support the Royal Australian Navy over the long term.
Source: BAE Systems Australia.
