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BOAT BUILDING

Polaris Marine Group offers specialist boat building services for commercial, government, and private clients across Australia. With a focus on craftsmanship, performance, and marine durability, we design and build vessels that meet the exact needs of their operators, whether for work, transport, or recreation. Our integrated boat building capability covers everything from steel and aluminium fabrication to outfitting, fitout, and sea trials. We work with clients to deliver new builds that meet specific operational, regulatory, and environmental requirements, with an emphasis on functionality, safety, and long-term performance.

Project Summary

Key Achievements

Custom Marine Vessels for Any Application

Polaris Marine Group designs and constructs custom marine vessels to meet a wide range of operational needs. These include workboats, barges, tugs, pontoons, crew transfer vessels, and survey boats, as well as passenger ferries and bespoke craft for harbour or offshore use. Each project starts with a clear understanding of how the vessel will be used, where it will operate, and the technical specifications it must meet. We then develop a build plan that balances engineering requirements with practical buildability and on-water performance. We have experience delivering vessels for: Port and harbour operations Marine construction and maintenance Commercial diving and dredging support Passenger and cargo transport Emergency and utility response

Steel and Aluminium Fabrication

Polaris Marine Group offers in-house steel and aluminium fabrication for marine vessels of all sizes. Our team of qualified fabricators, welders, and marine engineers works to exacting standards, ensuring structural integrity and compliance with Australian and international codes. We select materials based on the vessel’s purpose and operational environment, including corrosion resistance, impact strength, and weight requirements. All fabrication is carried out under controlled conditions to ensure weld quality, surface preparation, and dimensional accuracy. We fabricate hulls, decks, superstructures, engine mounts, tanks, and other structural components, with all work certified to the relevant maritime class or flag standards.

Fitout and Outfitting

Once the structural fabrication is complete, Polaris Marine Group undertakes a detailed fitout process to prepare the vessel for service. This includes mechanical and electrical systems, propulsion, fuel and ballast tanks, navigation equipment, and accommodation or control spaces. We work closely with clients and naval architects to ensure that the vessel’s systems are installed to specification, and that space is optimised for operational efficiency and comfort. Where required, we can install modular systems, wheelhouses, crew areas, and equipment platforms to suit the vessel’s role. All systems are tested and commissioned in line with safety regulations and manufacturer recommendations.

Integration With Marine Operations

Boat building is not just about constructing a vessel, it’s about creating an asset that performs in the real world. Polaris Marine Group integrates its boat building services with operational marine knowledge, ensuring that vessels are built for the environments and challenges they’ll encounter. Because we operate our own marine construction fleet, we understand the day-to-day demands placed on marine vessels. This informs our design input, build methodology, and materials selection, delivering boats that are not only compliant, but practical, durable, and efficient. We build vessels that work as hard as the people who use them.

Project Management and Client Collaboration

Each boat building project is managed by a dedicated team that works closely with the client, designer, and certification authority. From project planning and design development through to fabrication, fitout, and launch, we maintain clear communication and tight control over quality, cost, and delivery timelines. We assist clients in navigating approval processes, class inspections, and compliance documentation. Our transparent approach ensures that any technical or delivery risks are identified early and resolved proactively. Clients are welcome to visit the build site, observe progress, and be part of key decision-making milestones during the project lifecycle.

Sea Trials and Handover

Before a vessel is delivered, Polaris Marine Group conducts sea trials to test its systems, performance, and handling. These trials are essential for verifying compliance with design expectations and certifier requirements. During sea trials, we test propulsion, steering, stability, noise levels, electronics, and navigation systems. We simulate real-world operating conditions to ensure the vessel is safe, stable, and responsive. Any issues are logged, addressed, and resolved before final handover. Clients receive detailed commissioning reports, warranty documentation, and operational manuals as part of the handover process.

Repairs, Modifications, and Refit Work

In addition to new builds, Polaris Marine Group offers boat repair, modification, and refit services for commercial and government vessels. Whether it’s hull damage, structural upgrades, system replacements, or capacity modifications, our team provides fast, reliable solutions that meet marine standards. We can drydock, lift, or slip vessels for inspection and works, with minimal disruption to operations. Our experience working on high-use and mission-critical vessels ensures that modifications are delivered safely, efficiently, and with confidence in the outcome.

PROJECTS

SEE US IN ACTION

Manton Dam

Polaris Marine Constructions were engaged by Exact Contracting to provide a modular crane barge service at the Dam wall at Manton Dam to deliver the replacement of internal valving and upgrades to the infrastructure of the Intake tower.

Nelligen Bridge Marine Support and Demolition Contract

Polaris Marine Group played a key role in the Nelligen Bridge project, providing overwater support for construction before demolishing the 7-span, 5,000-tonne bridge. The in-house demolition was incident-free, using a suspended work deck with geotextile and drainage to capture debris. Materials were processed on-site and recycled. This project highlighted Polaris Marine’s expertise in complex marine demolition within sensitive waterways.

Seabed Services Pipe Line Deployment

Deploy 3 service pipe lines on the sea floor between Garden Island and Fort Dennison and cover with precast grout mattresses.

Fort Denison – Ferry Wharf

This project included wharf demolition, sea wall remediation, pile installation, concrete works, and the installation of a new pontoon with electrical connections.

Circular Quay – Western Promenade – Soffit Concrete Repairs

This project involved concrete remediation works, including hydro-blasting, shotcrete application, bar reinforcement, protective coatings, and concrete cutting, with site set-up, exclusion zones, and sound curtain installation to ensure safety and minimal disruption.

Manly Boat Shed – Pontoon & Jetty Replacement

This project involved constructing a pontoon, gangway, and timber jetty, including piling, demolition, and electrical connections, to deliver a durable marine access solution.
SEE MORE POLARIS PROJECTS

TESTIMONIALS

HEAR FROM SOME
OF OUR CLIENTS

★★★★★ 5/5
“Polaris are awesome to work with, they make landscaping jobs with tricky access a breeze.”

Johnny L - Distinct Landscapes

★★★★★ 5/5
“The attention to detail provided by PMC during the project could not be faulted. Execution, safety, onsite management and the finished product were at a very high standard. Communication throughout the project from PMC Supervisors and Project Manager were regular and accurate. This enabled Thales to understand daily activities, problems and overall progression at every stage. Ultimately, the professionalism shown by PMC through all aspects of the project, enabled for a successful end product to the Commonwealth. I can’t thank Dane and the PMC team enough for the way the project was ran, start to finish.”

Jake Duncombe, Project Manager

★★★★★ 5/5
“Polaris were an exceptional contractor to work with throughout this project. They were fluent in communication, timely, reliable, nailed the quality of work and went out of their way to be flexible with Thales needs. They have a positive and healthy working relationship with Thales.”

Owen Gardner, Project Manager

★★★★★ 5/5
“I have had the pleasure of working with Polaris for the last couple of years, particularly with transporting vehicles for events, deliveries, and contractors. Their Team is professional and reliable, from their Operational Team, Cookie & Jay, to their Skippers and deckhands are incredibly efficient, even under tight event schedules. What really stands out is their attention to detail and commitment to customer satisfaction. Such as accommodating last-minute changes, they always go the extra mile to make sure everything runs smoothly, giving us peace of mind. Over the years we have built a great relationship/partnership with Polaris and we look forward to continuing to work with them for years to come.”

Keighley O, Sydney Harbour Trust

GET IN CONTACT

If you need to tow it, show it, build it, push it, deliver it, lift it or salvage it over water; please complete this form and one of our team will be in touch.

Gate 2, James Craig Rd, Rozelle NSW 2039

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Phone: +61 2 9563 8333
Emergency Phone: +61 (0) 418 231 916

[email protected]

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Gate 2, James Craig Rd, Rozelle NSW 2039
[email protected]
Phone: +61 2 9563 8333
Emergency Phone +61 (0) 418 231 916
CERTIFICATION
BIMCO Certified
Certifications