Gulf South Shipbuilding Boom: 5 Steps How to Choose the Right Metal Forming Partner (Easy Guide for Project Managers)

The Gulf South is experiencing the biggest shipbuilding boom in decades. Major shipyards like Austal USA, Birdon, Main Iron Works, Silver Ships, and Steiner Shipyard are all expanding their operations. With billions in new investments flowing into the region, project managers are scrambling to secure reliable metal forming partners who can keep up with demand.

But here's the problem: not every metal forming company can handle the specialized requirements of marine and offshore projects. Choose the wrong partner, and you'll face delays, quality issues, and budget overruns that can sink your project before it even launches.

This guide breaks down the five essential steps to finding the right metal forming partner for your shipbuilding project.

Step 1: Verify Their Marine-Specific Experience

Not all metal forming is created equal. Shipbuilding requires specialized knowledge that goes far beyond basic plate rolling or cutting.

Look for partners who understand the unique challenges of marine fabrication:

• Corrosion resistance requirements for saltwater environments
• Complex hull geometries and compound curves
• Tight tolerances for watertight seals
• Specialized welding procedures for marine-grade steel

Ask potential partners about their experience with similar projects. Have they worked on barges, offshore platforms, or naval vessels? Can they provide references from other marine projects?

At Hooley Manufacturing, we've been forming steel for marine applications since 1908. Our plate forming capabilities have supported everything from small fishing vessels to major offshore platforms throughout the Gulf.

Step 2: Assess Their Current Capacity and Scalability

The Gulf South boom means everyone's busy. Austal USA just started construction on a 192,000 square foot assembly facility that won't be ready until summer 2026. Other yards are backlogged with military contracts and commercial orders.

You need a partner who can handle your project without stretching themselves too thin. Key questions to ask:

• What's their current capacity utilization?
• Do they have dedicated space for your project timeline?
• Can they scale up if your project requirements change?
• What's their typical lead time for projects similar to yours?

Be wary of partners who promise unrealistic delivery times or seem to be taking on more work than they can handle. A reliable partner will give you honest timeframes and may even turn down work to maintain quality for existing clients.

Step 3: Evaluate Their Equipment and Technology

Modern shipbuilding demands precision that's only possible with the right equipment. Your metal forming partner needs more than just basic rolling machines.

Look for partners with:

• CNC plasma cutting capabilities for precise shapes
• Multi-axis plate rolling machines for complex curves
• Heavy-duty cranes for handling large assemblies
• Climate-controlled facilities to prevent warping

The Gulf South's humidity can wreak havoc on steel if not properly controlled. Make sure your partner has the facilities to protect your materials throughout the fabrication process.

Step 4: Review Their Quality Control Systems

Quality issues in shipbuilding aren't just expensive: they can be dangerous. A failed weld or improperly formed plate can compromise the entire vessel's integrity.

Your metal forming partner should have documented quality control procedures that include:

• Material certification tracking
• Dimensional inspection protocols
• Welding procedure specifications
• Non-destructive testing capabilities

Ask to see their quality manual and recent inspection reports. ISO certification is a plus, but more importantly, they should be able to explain their quality processes in detail and show evidence of continuous improvement.

Step 5: Consider Their Financial Stability and Strategic Position

The shipbuilding boom has attracted billions in new investment, but it's also created volatility. Companies like Davie are investing $1 billion in Gulf Coast facilities, while new partnerships between major players like HD Hyundai and Huntington Ingalls are reshaping the competitive landscape.

You need a partner who's financially stable enough to weather these changes and invest in their capabilities. Red flags include:

• Frequent ownership changes
• Delayed payments to suppliers
• Aging equipment with no modernization plans
• Inability to provide financial references

Stable partners often have long-term relationships with major shipyards and a track record of completing projects even when market conditions change.

Making the Right Choice for Your Project

The Gulf South shipbuilding boom creates tremendous opportunities, but success depends on choosing partners who can deliver quality work on time. Don't be swayed by the lowest bid: focus on finding partners with the right combination of experience, capacity, equipment, quality systems, and financial stability.

The ongoing investments in Gulf Coast shipbuilding suggest this boom will continue for years. Government initiatives like the SHIPS for America Act are driving sustained demand for both military and commercial vessels. Projects that start today may extend well into the next decade.

That makes your choice of metal forming partner even more critical. The partner you choose now could become a key relationship for multiple future projects. Take the time to evaluate them properly using these five steps, and you'll set yourself up for success in this rapidly growing market.

Remember, the cheapest option isn't always the best value. In an industry where delays can cost millions and quality issues can be catastrophic, investing in the right partner from the start pays dividends throughout your project: and beyond.

Barge Repair to Offshore Marine: Why 117 Years of Experience Still Matters in 2025

When you're dealing with Gulf Coast marine projects, there's something to be said for working with people who've seen it all before. At Hooley Manufacturing, we've been forming, rolling, and cutting metal for shipbuilding and marine work since 1907. That's 117 years of watching the industry evolve, learning from every project, and passing knowledge down through generations.

Sure, technology has changed dramatically since our early days. But here's what hasn't changed: the need for precision, reliability, and someone who understands exactly what you're up against when you're working on everything from barge repairs to offshore marine platforms.

The Gulf South Advantage: Local Knowledge That Runs Deep

Working in Gulf South marine means dealing with specific challenges that folks up north just don't face. The saltwater environment, hurricane seasons, and the unique demands of everything from shrimp boats to offshore rigs require a different kind of expertise.

We've watched shipyards come and go, seen boom and bust cycles, and worked through every major storm that's hit the region. That kind of institutional memory matters when you're planning a project. We know which materials hold up best in our climate, which designs work for local conditions, and how to anticipate problems before they become expensive headaches.

When a customer calls us about a barge repair project, we're not just thinking about the immediate fix. We're considering the vessel's operating environment, its age, the typical stress points we've seen on similar barges, and how to make repairs that will last. That's the kind of insight you only get from decades of hands-on work in the Gulf.

Multi-Generational Problem Solving

Here's something you don't get with newer shops: multiple generations of craftsmen who've worked side by side, sharing knowledge and techniques. Our team includes people whose grandfathers worked here, and they've inherited not just skills, but stories about how different approaches worked out over the years.

This generational knowledge transfer means we've got solutions for problems that others haven't even seen yet. When someone brings us a complex plate forming challenge for an offshore platform, we're drawing on decades of similar projects. We know which shortcuts to avoid, which techniques save time without sacrificing quality, and how to spot potential issues early.

The younger guys on our team bring fresh perspectives and familiarity with new technologies, while the experienced hands provide the wisdom that only comes from making and learning from mistakes over many years. It's a combination that's hard to replicate at shops that started yesterday.

From Sketches to Solutions: Design Help That Works

One thing that sets experienced metal fabricators apart is the ability to work with customers who have great ideas but need help with the technical details. We regularly take projects that start as rough sketches on napkins and turn them into precise, functional components.

This isn't about ego – it's about efficiency. When you've seen thousands of metal forming projects, you develop an instinct for what will work and what won't. We can often suggest design modifications that will save you money, improve performance, or make installation easier. Sometimes it's as simple as changing a bend radius slightly, or switching to a different approach entirely.

For marine projects especially, this design assistance can be crucial. The environment is unforgiving, and what looks good on paper doesn't always work when you're dealing with saltwater, constant vibration, and the need for components to last for decades.

Speed When You Need It Most

The marine industry doesn't wait for anybody. When a vessel is down for repairs, every day costs money. When you're building to meet a delivery deadline, delays can kill a project's profitability.

Our 117 years in business means we've built relationships with suppliers, developed efficient processes, and learned how to prioritize work to meet tight deadlines without cutting corners. We understand which projects can be rushed and which need extra time, and we're honest about what's realistic.

More importantly, we've got the equipment and expertise to handle rush jobs properly. Our plate rolling and plate forming capabilities can tackle complex shapes quickly, and our CNC cutting services ensure precision even when we're moving fast.

Reliability That Keeps Projects on Track

In marine work, reliability isn't just about meeting deadlines – it's about safety. When we're forming components for offshore platforms or cutting parts for vessel repairs, there's no room for "close enough." Lives depend on this work being done right.

Our long track record speaks for itself. Companies keep coming back to us, sometimes for decades, because they know we deliver what we promise. That kind of consistency comes from having systems in place, quality controls that work, and people who take pride in their craft.

We've survived 117 years by being the kind of partner that customers can count on. When you call us about a project, you're not just getting our current capabilities – you're getting all the lessons learned, relationships built, and reputation earned over more than a century in business.

Cost Efficiency Through Experience

Experience saves money in ways that aren't always obvious upfront. We can often suggest more cost-effective materials or manufacturing methods because we've tried different approaches on similar projects. We know which suppliers offer the best value, and we've got relationships that can sometimes help with pricing or priority scheduling.

Our corrugating services, for example, benefit from decades of experience with different materials and applications. We can help customers choose the right approach for their specific needs rather than defaulting to the most expensive option.

Just as importantly, our experience helps avoid costly mistakes. We've seen what happens when projects are rushed without proper planning, when the wrong materials are chosen for the application, or when design issues aren't caught early. Learning from others' experience is a lot cheaper than learning from your own mistakes.

Ready to Put Our Experience to Work for You?

Whether you need a single custom component or you're planning a major marine fabrication project, our 117 years of Gulf South experience can make a difference. We've worked on everything from small boat repairs to massive offshore structures, and we approach each project with the same attention to detail and commitment to quality.

Don't take our word for it – let us show you what more than a century of metal forming expertise can do for your project. Contact us today for a quick, free estimate. We'll take the time to understand your specific needs and provide honest advice about the best approach for your timeline and budget.

Visit us at hooleyinc.com or contact us directly to get started. In a business where experience matters, 117 years gives you an advantage that's hard to beat.

The Gulf South Shipbuilding Boom: What It Means for Your Metal Forming Needs

If you've been keeping an eye on the Gulf Coast lately, you've probably noticed something exciting happening. Shipyards are busier than they've been in years, cranes are working overtime, and there's a real sense that American shipbuilding is making a comeback. This isn't just good news for the maritime industry: it's creating massive opportunities for metal forming companies like ours.

The numbers tell the story. Just this past July, the federal government announced $8.75 million in grants through the Maritime Administration's Small Shipyard Grant program, with nine of the 17 awarded shipyards located right here along the Gulf Coast and inland waterways. That's serious money flowing into our region, and it's just the tip of the iceberg.

What's Driving This Shipbuilding Renaissance?

Several factors are coming together to create this perfect storm of opportunity in Gulf South shipbuilding.

Federal Investment and National Security Priorities

The federal government has finally woken up to the fact that America's shipbuilding capacity is embarrassingly small compared to our global competitors. While China builds nearly half of all commercial ships worldwide, the U.S. produces less than 1% of global commercial vessels. Over the past decade, China launched 6,765 commercial ships while we managed just 37. That's not just a trade imbalance: it's a national security issue.

The Small Shipyard Grant program has distributed over $320 million since 2008, and the momentum is building. Proposed legislation like the SHIPS for America Act would require certain vessels to be built in U.S. shipyards under American regulations, creating sustained demand for domestic suppliers.

Offshore Energy Diversification

Here's where things get really interesting for metal forming companies. Gulf Coast shipyards are no longer just focused on oil and gas: they're pivoting to offshore wind and other renewable energy projects. This diversification is smoothing out the boom-bust cycles that traditionally plague energy-dependent shipyards, creating more consistent demand for fabrication services year-round.

Austal USA in Alabama is a perfect example. They've invested heavily in steel manufacturing capabilities to complement their aluminum expertise, positioning themselves to serve both Navy and Coast Guard steel ship requirements. When major players like this expand their metal working capabilities, it creates ripple effects throughout the entire supply chain.

Supply Chain Advantages

One thing that makes the Gulf South particularly attractive for shipbuilding is our established supply chain network. Steel comes from Alabama, North Carolina, and Texas. Engines and controls arrive from Indiana, Georgia, and Ohio. Fabrication and components flow in from Wisconsin, Illinois, Pennsylvania, and dozens of other states. This national network creates opportunities for metal forming companies across the region to get involved in shipbuilding projects.

What This Means for Metal Forming Demand

The shipbuilding boom translates directly into increased demand for virtually every type of metal forming service you can imagine.

Diverse Manufacturing Requirements

Modern shipbuilding utilizes almost every metal forming method in the book. We're talking about sheet metal production using rolling mills, die casting for complex engine housings, sand casting for large structural components like hull sections, powder metallurgy for precision parts, and extensive extrusion work. If you can form, cut, bend, or shape metal, there's probably a place for your services in this supply chain.

Plate Work Takes Center Stage

Here at Hooley Manufacturing, we're seeing particularly strong demand for plate forming and cutting services. Shipbuilding requires massive amounts of precisely formed plate work: hull sections, bulkheads, deck plates, and structural components that need to meet exact specifications while handling the stresses of marine environments.

Quality and Precision Requirements

Shipbuilding isn't forgiving when it comes to quality. Components need to meet strict maritime standards, handle saltwater corrosion, and perform reliably in challenging conditions. This creates opportunities for metal forming companies that can deliver consistent, high-quality work while meeting tight deadlines.

The good news? North American metal fabricators have significant competitive advantages. We offer qualified suppliers with established reputations, in-house logistics capabilities, and the flexibility to work closely with shipbuilders on custom solutions. Long-term partnerships eliminate the need for shipyards to maintain extensive in-house metalworking divisions while providing ongoing technical advice for material selection and specialized applications.

How Hooley Manufacturing Fits Into This Picture

We've been serving the marine and heavy industrial markets for decades, so this shipbuilding boom feels like a natural fit for our capabilities. Our experience with precision plate forming, fast turnarounds, and ability to work from anything: detailed blueprints or rough sketches: puts us in a perfect position to support shipyard projects.

Decades of Marine Industry Experience

We've been forming metal for marine applications long before this current boom started. That experience matters when you're dealing with the unique challenges of maritime fabrication: understanding how different alloys behave in marine environments, knowing which forming techniques work best for specific applications, and having the expertise to suggest improvements to original designs.

Speed When It Matters

Shipyard projects often work on tight timelines, especially when vessels are in dry dock for repairs or modifications. Our reputation for fast turnarounds isn't just nice to have: it's essential when a delayed delivery could mean keeping a multi-million-dollar vessel out of service for extra days or weeks.

Flexibility in Project Requirements

One thing we love about shipyard work is the variety. Some projects come with detailed engineering drawings and specifications. Others start with a quick sketch on a napkin and a phone call saying "we need this part by Friday." Our team thrives on both types of challenges, and we've built our processes to handle everything from precisely engineered components to rapid-fire custom fabrication.

Industries We're Supporting

The Gulf South shipbuilding boom isn't limited to traditional commercial vessels. We're seeing increased activity across multiple maritime sectors:

Shipbuilding and New Construction

New vessel construction creates demand for everything from structural components to specialized fittings. Whether it's commercial cargo ships, military vessels, or specialized work boats, new construction projects require extensive plate forming and custom fabrication work.

Offshore Marine and Energy

The offshore energy sector: both traditional oil and gas and renewable wind projects: requires specialized vessels and platforms. These projects often need custom-formed components that standard suppliers can't provide, creating opportunities for flexible fabricators like us.

Barge Repair and Modification

The inland waterway system is busier than ever, and that means more wear and tear on the barge fleet. Repair and modification work keeps vessels operating efficiently while extending their service life. This sector provides steady, consistent demand for plate forming and custom fabrication services.

Heavy Industrial Marine Support

Ports, terminals, and marine service facilities need ongoing support for everything from loading equipment to dock infrastructure. These projects often require heavy-duty formed components that can handle the demanding marine environment.

The Opportunity Is Now

The Gulf South shipbuilding boom represents more than just a temporary uptick in maritime activity: it's a fundamental shift toward rebuilding American maritime capabilities. For metal forming companies positioned to serve this market, the opportunities are significant and likely to continue growing.

Success in this market requires understanding the unique demands of maritime applications, maintaining the quality standards the industry demands, and building the relationships necessary to become a trusted partner rather than just another supplier.

At Hooley Manufacturing, we're excited about what this boom means for our customers and our community. We've got the experience, equipment, and expertise to help shipyards and marine contractors get their projects done right and on time.

Ready to Get Started?

Whether you're working on new construction, repairs, modifications, or custom projects, we'd love to discuss how our metal forming capabilities can support your shipyard operations. From detailed engineering drawings to rough sketches, we can help turn your ideas into precisely formed metal components.

Don't let project delays keep your vessels out of service longer than necessary. Contact us today for a fast estimate on your next plate forming or custom fabrication project. Let's talk about how Hooley Manufacturing can help you take advantage of the Gulf South shipbuilding boom.

From Sketch to Steel: How to Get Perfect Results from Your Plate Cutting and Forming Job

Cutting and forming plate doesn’t need to be complicated. Clear inputs, the right process, and tight checks deliver fast, clean parts. Here’s a simple, practical guide to get it right the first time.

Start with clear drawings

Strong results start with complete, readable drawings and files.

• Send clean DXF/DWG/STEP files plus PDFs.
• Call out material grade and thickness on every sheet.
• Add overall dimensions, hole sizes, and tolerances. Mark which dimensions are critical.
• Show grain direction and bend lines/arrows.
• Specify inside bend radii and bend order.
• Note edge quality (laser/plasma/waterjet) and any deburr or grind requirements.
• Include quantity, target delivery date, and finish needs (as-cut, pickled, blasted, primed).
• For formed parts, provide “after forming” reference dimensions.
• Keep holes, slots, and notches away from bend lines when possible.
• Allow tabs or lead-ins away from critical edges to protect finish surfaces.

We use CAD/CAM to develop blanks, bend allowances, and nests to reduce waste and hold tolerance.

No drawings? We’ll help.

You don’t need a full print to get started with Hooley.

• We can work from a template, a sample part, field measurements, photos, or a napkin sketch.
• Got only an idea? Call us. We’ll help shape it into a practical design.
• Our design team will create or clean up drawings, pick materials, and plan bends and rolls with you.
• We’ll explain options, costs, and lead times so you can choose what fits.

Send what you have and we’ll get moving.

Choose the right material

Pick the plate that matches the job and the forming need.

• Carbon steel (A36, A572, HSLA): cost-effective, weldable, good general purpose. HSLA holds strength with lower weight.
• Stainless (304/316): corrosion resistance and clean finish; expect more springback in forming.
• Aluminum (5052, 6061): light and formable; 5052 bends easier, 6061 may need larger radii.
• Grain direction affects bending and rolling. If direction matters, mark it.
• Ask for MTRs and heat traceability if your project requires it.

Pick the right cutting method

Choose based on thickness, tolerance, edge quality, and budget.

• Laser: tight tolerances, smooth edge, minimal HAZ. Great for thin to medium plate and detailed geometry.
• Plasma: fast and cost-effective for thicker plate. Expect more taper and HAZ; plan for cleanup on critical edges.
• Waterjet: no heat, excellent for tight features and heat-sensitive materials. Slower and often higher cost.

Tell us which edges are cosmetic or critical. We’ll pick lead-ins, pierce points, and cut order to protect them.

Forming basics

Good forming starts with correct radii, tonnage, and sequence.

• Press brake jobs need inside bend radius, angle, and orientation. We’ll size the die opening to suit the material and thickness.
• Allow for springback. Specify the final angle; we will compensate in setup.
• Check minimum flange lengths, bend reliefs, and corner reliefs to avoid tearing and distortion.
• Call out bend allowances/deductions or the K‑factor used in your flat pattern.
• Rolling: provide finished ID/OD, seam gap, straight sections, and out-of-round limits. Minimum roll diameter depends on material, thickness, and grade.
• Very heavy plate may require larger radii or staged/bump forming. We will advise if adjustments are needed.

Quality checks

Build quality into the process so parts fit on site.

• First-article inspection available on request.
• Verify critical dimensions at each step (after cut, after form).
• Define flatness requirements and where they apply (as-cut vs. after forming).
• Specify burr, HAZ, and scale removal where needed.
• Maintain tool condition and machine calibration to hold repeatability.
• Traceability: we can mark part numbers and heat numbers and include MTRs.

Plan the workflow

Good sequencing saves time and avoids scrap.

• Cut, then form, then heat treat or finish as required. If parts are tight-tolerance, rough cut, stress relieve (if specified), then finish cut.
• Minimize handling. Plan lift points for heavy plate to prevent distortion and surface damage.
• Protect critical faces during handling and shipping. Use skids, spacers, and wraps as needed.

For complex geometries

Tough parts often need special setups and tooling.

• Custom dies, segmented tooling, and bump forming can achieve tight shapes in heavy plate.
• Trial blanks or short-run prototypes help dial in bend allowances and springback.
• If heat treatment is required, plan its order relative to forming to protect properties and dimensions.
• Allow lead time for tooling design and procurement.

The bottom line

Clear drawings, the right material, the right cutting method, and controlled forming deliver fast, accurate parts. Tell us what matters most—tolerance, finish, speed—and we’ll build the process around it. Estimates are free and timely.