Sturgeon Bay, Wisconsin has established itself as one of the Midwest’s most significant shipbuilding centers. From humble beginnings in the 19th century to its modern operations, this maritime hub has shaped both the local economy and America’s shipbuilding industry as a whole.
Sturgeon Bay’s shipbuilding tradition began in the mid-1800s when the area’s natural harbor and abundant timber resources attracted early entrepreneurs. The first recorded commercial shipyard was established in 1862 by Joseph Harris Sr., focusing primarily on wooden schooners to serve the booming lumber industry. The completion of the Sturgeon Bay Ship Canal in 1882 proved transformative, connecting Lake Michigan directly to Green Bay and positioning the city as a strategic maritime waypoint.
As the 19th century gave way to the 20th, wooden shipbuilding gradually transitioned to steel construction. This evolution mirrored broader industrial changes sweeping across America’s Great Lakes region. The Smith Brothers Shipyard, founded in 1899, was among the first to embrace steel shipbuilding techniques, setting the stage for the city’s future prominence.
The most significant chapter in Sturgeon Bay’s shipbuilding story began in 1918 with the establishment of what would eventually become Bay Shipbuilding Company. During both World Wars, the shipyards operated at full capacity, producing military vessels and contributing significantly to America’s naval efforts. The World War II era particularly accelerated growth, with employment numbers reaching unprecedented levels.
In the post-war period, Bay Shipbuilding adapted to changing maritime demands by specializing in Great Lakes bulk carriers, car ferries, and other commercial vessels. The company’s expertise in ice-strengthened hulls—crucial for winter navigation on the Great Lakes—became a particular specialty that distinguished it from coastal shipyards.
Today, Sturgeon Bay’s shipbuilding industry is anchored by Fincantieri Bay Shipbuilding, the successor to Bay Shipbuilding following Italian shipbuilding giant Fincantieri’s acquisition in 2008. The facility occupies over 60 acres of waterfront property and houses massive construction and repair facilities, including one of the largest floating dry docks on the Great Lakes.
The shipyard specializes in building and maintaining commercial vessels including articulated tug-barges, dredges, and various specialized watercraft. The yard’s winter fleet service program, which maintains and repairs Great Lakes vessels during the ice season, remains a critical component of the business.
Beyond Fincantieri, Sturgeon Bay is home to other maritime businesses such as Palmer Johnson (historically known for luxury yachts) and numerous marine engineering and service companies that form a comprehensive maritime industrial cluster.
Shipbuilding remains a cornerstone of Sturgeon Bay’s economy. The industry employs hundreds of skilled workers including welders, electricians, engineers, and designers, offering some of the region’s highest-paying manufacturing jobs. These positions support families throughout Door County and contribute substantially to the local tax base.
The shipyards also indirectly support numerous supplier businesses and service industries throughout northeastern Wisconsin. When shipbuilding activity peaks, the economic ripple effect touches everything from steel suppliers to local restaurants and housing markets.
Modern shipbuilding in Sturgeon Bay has evolved to address growing environmental concerns and technological advancements. Fincantieri Bay Shipbuilding has implemented more environmentally conscious construction methods and builds vessels with advanced emission control systems. The yard has also constructed some of the first liquefied natural gas (LNG)-powered vessels for Great Lakes service, representing the industry’s shift toward cleaner marine propulsion.
Digitalization has transformed the shipbuilding process, with computer-aided design replacing traditional drafting methods and automation enhancing productivity throughout the yards. These technological advancements have required continuous workforce development to maintain the specialized skills needed for modern shipbuilding.
Beyond its economic significance, shipbuilding has shaped Sturgeon Bay’s cultural identity. The Door County Maritime Museum preserves this heritage through exhibits featuring shipbuilding tools, vessel models, and photographs documenting the evolution of this crucial industry. The museum’s centerpiece is the restored tug John Purves, offering visitors a tangible connection to the area’s maritime past.
Annual events like the Sturgeon Bay Maritime Week celebrate this heritage while educating visitors about the continued importance of shipbuilding and maritime commerce to the region.
Despite its historical resilience, Sturgeon Bay’s shipbuilding industry faces significant challenges. Global competition, particularly from Asian shipyards with lower labor costs, has pressured American shipbuilding generally. The cyclical nature of maritime construction creates periods of boom and bust that affect workforce stability.
However, several factors suggest continued viability. Specialized knowledge of Great Lakes requirements, proximity to customers, and the Jones Act (requiring vessels operating between U.S. ports to be American-built) provide competitive advantages. The increasing age of the Great Lakes fleet also promises steady repair and replacement work for decades to come.
Recent investments in facilities and technology demonstrate confidence in the industry’s future. In 2020, Fincantieri announced a $30 million shipyard expansion to accommodate larger vessels and increase efficiency, signaling a commitment to Sturgeon Bay as a long-term production center.
From wooden schooners to modern steel vessels, shipbuilding has been woven into Sturgeon Bay’s identity for over 150 years. The industry has demonstrated remarkable adaptability through technological shifts, economic cycles, and changing maritime needs. As it navigates the challenges of global competition and environmental regulations, Sturgeon Bay’s shipbuilding tradition continues to evolve while remaining fundamentally connected to its historical roots—a testament to the resilience of this small Wisconsin city’s maritime legacy.