Future Carrier to Feature More Prebuilt Parts

CVN 79

The Navy and Newport News Shipbuilding are working on new shipbuilding methods and making early progress with initial construction of the second, next-generation Ford-class aircraft carrier slated to enter service in March 2023 — the John F. Kennedy, or CVN 79.

The construction strategy for the Kennedy, which is thus far only 6 percent built, is using a handful of techniques intended to lower costs and call upon lessons learned from the building of the first Ford-class carrier in recent years, the USS Gerald R. Ford. The Ford was christened in November, is now undergoing additional testing and slated to enter service in 2016.

The Navy was criticized by lawmakers and government watchdog groups during the construction of the Ford for its rising costs. As of last year, construction costs for the ship were estimated at $12.8 billion, several billion dollars above previous figures.

Navy officials point out that at least $3 billion of the Ford’s costs are due to what’s described as non-recurring engineering costs for a first-in-class ship such as this. Nevertheless, they say the service is making progress with efforts to lower costs for the Kennedy.

“Through lessons learned and an intense, focused effort to improve the way carriers are built, we are confident in substantial cost reduction on CVN 79,” Rear Adm. Thomas Moore, program executive officer for carriers, told Military.com in a written statement.

Newport News Shipbuilding, which is a subsidiary of Huntington Ingalls Industries Inc., is now assembling the lower portions of the Kennedy under a construction preparation contract with the Navy.

The construction preparation contract affords the shipbuilder an opportunity to gather and purchase materials and parts for the ship while beginning initial assembly. Of the 1,128 total structural units that comprise the Kennedy, 654 of them are covered under the construction preparation contract, said Mike Shawcross, vice president of Kennedy carrier construction.

More than 230 structural units have already been completed on items such as pipe assemblies, cabling, shafts, rudders and struts, he said.
Newport News Shipbuilding is able to buy larger quantities of parts earlier in the construction process with the Kennedy because, unlike the circumstance during the building of the Ford, the Kennedy’s ship design is already completed, Shawcross explained.

In addition, one of the construction techniques for the Kennedy includes assembling compartments and parts of the ship before moving them to the dock, he said. Production lines have been started for groups of ship units that are similar, he said.

Construction begins with the bottom of the ship and works up with inner-bottoms and side shells before moving to box units, Shawcross explained. The bottom third of the ship gets built first.

As for the design, the Kennedy will be largely similar to the design of the Ford, with a few minor alterations. The aircraft elevators on the Kennedy will use electric motors instead of a hydraulic system to lower costs, Shawcross added.

Also, some of the design methods have changed such as efforts to fabricate or forge some parts of the ship instead of casting them because it makes the process less expensive, he said.

USS John F Kennedy CVN 79 People Working

The Kennedy will replace the USS Nimitz, which is due to retire by 2027; the Ford-class carriers are slated to replace the existing Nimitz-class carriers on a one-to-one basis in an incremental fashion over the next half century or so.

“We are moving towards a construction contract being awarded this year and anticipate that the Christening ceremony will take place in September of 2020, with a scheduled delivery to the fleet in March 2023,” Kennedy program manager Capt. Doug Oglesby said in a written statement.

Built with a host of new technologies to improve operational performance and efficiency over the existing Nimitz-class carriers, the Ford-class ships are engineered with slightly larger deck space to allow for a greater sortie rate, more computer automation to reduce the need for manpower and an electromagnetic catapult to propel jets off the deck an into the sky over the ocean.

The new electromagnetic catapult system and new advanced arresting gear are designed for smoother, safer and more efficient take-offs and landings compared to the steam catapults now used on today’s carriers.
Also, the Ford-class carriers are being built with three times the electrical power generating capacity compared to Nimitz-class carriers, Moore said.

The USS Ford will have four 26-megawatt generators bringing a total of 104 megawatts to the ship. This helps support the ship’s developing systems such as its Electro-Magnetic Aircraft Launch System, or EMALS, and provides power for future systems such as lasers, and rail-guns.

The ships are engineered with a redesigned island, slightly larger deck space and new weapons elevators in order to achieve a 33-percent increase in sortie-generation rate. The new platforms are built to launch more aircraft and more seamlessly support a high-op tempo, Navy officials said.

The new weapons elevators allow for a much more efficient path to move and re-arm weapons systems for aircraft. The elevators can take weapons directly from their magazines to just below the flight deck, therefore greatly improving the sortie-generation rate by making it easier and faster to re-arm planes.

About the Author

Kris Osborn
Kris Osborn is the managing editor of Scout Warrior and a former associate editor at Military.com.

18 Comments on "Future Carrier to Feature More Prebuilt Parts"

  1. Improved missle technologies are going to make Carriers very vulnerable. Anti-ship weapons that can put a Carrier at risk are going to become cheaper while Carrier defense will require the development of very expensive new technology. It might be time to totally rethink force projection strategies.

  2. The last time a carrier was attacked was what, 1945? Nobody has seriously tried to damage a carrier. To my knowledge, nobody has seriously tested Anti-Ship Missile defenses. How about a BRAHMOS with dummy warhead vs. ESSM and SEARAM, installed on a ship ready for scrap?

  3. WTB: 3D printer large enough to accommodate aircraft carrier sections

  4. I wonder how long it will be untilt the EMALS and AAG work reliably. There have been land-based tests, but according to DOT&E, the failure rates have been very high. DOT&E's report from February says there had been 201 chargeable failures out of 1,967 launch attempts with the EMALS, and 9 chargeable failures out of 71 attempted arrests with the AAG. And I would imagine that the failure rates would be at least this bad when the systems are incorporated on a ship.

    I don't know how these technologies have progressed since this report was issued earlier this year. Hopefully they will be ready when the Kennedy is ready. The concurrent development approach to acquisitions has gotten us into a lot of trouble with the LCS and the F-35, though, and may be problematic for the Kennedy program, too. Perhaps someone with direct knowledge can comment?

  5. They need to stop naming these ships after politicians and start naming them after actual military men. Kennedy, Bush and the Theodore Roosevelt are fine though.

  6. Anyways, Hopefully US Congress will work out their funding issues they have with the military. Right now, the USS George Washington CVN-73 is about start process of planning for its DEFUELING. Their complaining about how much the prototype Ford Class ship costs? They can't maintain the current fleet at this rate.

  7. We opted for a 12-carrier navy knowing that a number of carriers would be in for availability and refueling. If the Ford's reactors are as efficient as they say they are they will not require the refueling…which accelerates turnaround time considerably. We can probably get by with ten Fords in lieu of 12 Nimitz'.

  8. Instead of decommissioning the older Nimitz-class carriers we should be selling them to our allies.

  9. FRANCE ?.

    Mon Dieu !, It could not be !.

    The French go it their own on everything. Regardless of how much it costs.

  10. I am curious though, I thought the EMALS and arresting gear was a mostly complete system(s) ?.

    Are they really installing this stuff on Ford, not sure it's going to work, hoping to get it to work before the ship goes into service ?.

    Yeah, I know, done all the time. But unlike an semi-functional F35, when you have a fleet of legacy aircraft sitting around, in this case if the catapult and arresting systems don't work as advertised, the ship is useless and is only 1 of 10 carriers.

  11. stephen russell | August 6, 2014 at 6:38 pm | Reply

    why not use 3D printing & save there alone & automate to reduce ships crew overall
    Save money BIG time for such carriers.
    Use Nimitz type for training with Gerald R Ford systems installed for crews.

  12. Brian B. Mulholland | August 6, 2014 at 8:17 pm | Reply

    It is disconcerting that we still haven't developed a point defense system from a clean sheet of paper to protect warships – let alone the huge assets like carriers. RAM started as a Sidewinder derivation, Sea Sparrow and the Evolved edition – all grew out of hardware designed for very different use.

    I wish we'd go in with the UK on CAAM. Shortranged, but so what? We won't see future missiles coming until they're almighty close. A cold-launched missile, small, so it would fit more easily then most weapons on LCS (let's not go there in this thread.)
    Active terminal guidance, so a major injury to a big antenna might not totally cripple a launched missile.

  13. Pipe dream. Half of the US carrier fleet will have to be retired as the dollar crashes in the coming 2-3 years. Profligacy and political madness have their consequences.

  14. This time, in "Final Countdown", we will leave the Nimitz BACK in 1941 to fight the Japanese fleet at Pearl Harbor, and put a new slant on history.

  15. Pre assembled uniform parts were first properly implimented with military ship building with the HMS Dreadnaught.

    Nice to see the US Navy is stepping up and using 100 year old management processes.

  16. How are the four 26-megawatt generators hardened from attack? Take these out and the ship is dead in the water for flight operations. What are the back-up systems if this new technology should fail?

  17. Why are we naming another ship " Kennedy"? There are other presidents that need recognition. Kennedy was in office for only 2 years!

  18. The Ford was already supposed to showcase modular pre-built CHEAPER construction. Surprise surprise cost overruns in the billions. Bid too cheap, lock in the program, then charge whatever you want because there's no going back, typical military procurement scam. Nice piece of kit though, still the most versatile weapons group in the world.

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