BAE Systems Jacksonville Ship Repair - Shiplift Dy-Docking Complex

Abstract: BAE Systems Jacksonville Ship Repair (BAEJSR) is poised to revolutionize ship docking in Florida and globally with its groundbreaking shiplift system, one of the world's largest, boasting a remarkable lifting capacity. Amidst an ambitious expansion initiative totaling over $200 million, BAE's latest endeavor involves the establishment of a state-of-the-art vertical ship lift and dry-docking complex. This cutting-edge infrastructure enhancement aims to bolster the industrial capacity vital for national security and the sustained growth of the U.S. and international maritime sectors.
The new shiplift system will be approximately 500 ft. long and 110 ft. wide capable of handling vessels via Self Propelled Modular Transporters (SPMT’s) of nearly 25,000 tons, including prominent naval assets such as the U.S. Navy’s Ticonderoga-Class Guided Missile Cruiser, the Arleigh Burke-Class Guided Missile Destroyer, both the Freedom and Independence-Class Littoral Combat Ships and the recently named Constellation-Class Frigates.
BAEJSR is augmenting its shipyard capabilities through the development of a new land-level dry-docking facility. This facility, slated to accommodate up to four large-hulled ships simultaneously, is set to significantly enhance dry-docking capacity, thereby facilitating seamless maintenance operations and reducing downtime for essential vessels. The benefits of this comprehensive expansion initiative are diverse. By tripling dry-docking maintenance space, BAE aims to streamline operational efficiency while minimizing environmental impacts through effective waste containment and pollution reduction measures. The enhanced facility layout enables concurrent work on multiple vessels, further optimizing resource utilization and maximizing productivity.
The project included a dredge design to dredge the basin to a depth of -60 NAVD88 to accommodate the shiplift platform footprint operational requirements and included placement of over 200,000 cubic yards of material to offshore ocean disposal in advance of pier construction. Construction of the Shiplift Marine Infrastructure began with the initiation of the transfer bridge construction. The transfer bridge serves as a crucial connection between the land-level facility and the shiplift platform. This complex structure comprises reinforced concrete beams and decks, integrated into the existing bulkhead and relieving platform structure on the landside. Precast prestressed concrete piles, ranging from 24 to 30 inches square, support the landside, while steel pipe piles, 36 inches in diameter, with lengths of 140 feet, provide support on the shiplift basin waterside. The project faced challenges due to unique geological conditions and stringent design requirements, necessitating innovative solutions from the technical team.
Additionally, construction of the Ship Lift Marine Infrastructure commenced in March 2024, focusing on the installation of finger piers. Pile driving activities involved 60-inch diameter steel pipe piles, 160 feet in length, and 36-inch diameter steel pipe piles, 140 feet in length. To support the structural pier deck accommodating the shiplift hoists, the design team opted for a precast stay-in-place form system. This system ensures stability and efficiency during construction, facilitating the installation of twenty-eight shiplift hoists on each pier. These construction activities demonstrate a commitment to precision engineering and the implementation of innovative techniques to overcome challenges and ensure the project's success.

How does this project / topic contribute to the advancement of the industry and profession?: BAE Systems' expansion project at the Jacksonville Ship Repair facility advances the industry by upgrading infrastructure, enhancing operational capabilities, and promoting efficiency. It sets new standards for ship repair facilities worldwide, boosts capacity and capability, and drives cost-effectiveness through innovation. Additionally, the project emphasizes environmental sustainability, compliance with regulations, and technological innovation. By creating opportunities for skills development and training, it ensures the proficiency and competitiveness of professionals in the field. Overall, this project contributes significantly to the advancement of the ship repair and maintenance industry, fostering growth, sustainability, and excellence.

Does the project / topic implement new and innovative techniques, materials, technologies, and delivery methods?: It introduces cutting-edge infrastructure such as the vertical ship lift and land-level dry-docking complex, which utilize advanced construction methods and engineering solutions. Additionally, innovative foundation support systems are employed to reinforce low shear strength soils and mitigate foundation settlements. The project incorporates state-of-the-art equipment and systems for fire suppression, stormwater treatment, and operational support. Overall, these advancements demonstrate a commitment to embracing technological innovation and driving continuous improvement in ship repair and maintenance practices.

What was the most challenging aspect of your project / topic and how did you handle it to ensure success?: The most challenging aspect of the project was overcoming the complex geological conditions and technical requirements inherent in constructing the land-level dry-docking facility. We addressed this challenge by collaborating closely with geotechnical industry experts and contractor during construction to devise innovative foundation support systems. By utilizing advanced construction techniques and materials, we ensured the structural integrity and stability of the facility. Additionally, meticulous planning and proactive risk management strategies were implemented to mitigate potential challenges and ensure project success.

Who is the target audience for this paper?: Waterfront engineers, dredge engineers, ocean engineers, oceanographers, sediment and coastal modeling engineers, environmental scientists, marine terminal operators, and environmental reviewers could benefit from hearing a discussion of this project. The lessons learned by our team of waterfront engineering team in working with sediment modeling scientists will be valuable to anyone interested in dredging, sediment transport models, or terminal operations.