Shiplift Dry Docking Complex

Background

The BAE Systems, Inc. Jacksonville Ship Repair facility in Florida is located at the intersection of the St. Johns River and the Atlantic Intracoastal Waterway, adjacent to the U.S. Naval Station Mayport. The shipyard has a long history of vessel repair, maintenance, overhaul, conversion, and marine fabrication for domestic, international, commercial, and government customers, from tugs and mega-yachts to tankers and warships. As part of a more than $200 million facility expansion, BAE 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, and an enhanced dry-docking complex. This cutting-edge shipyard infrastructure enhancement is needed to bolster the industrial capacity vital for national security and the sustained growth of the U.S. and international maritime sectors.

Approach

The new shiplift system will be nearly 500 ft. long and 110 ft. wide, capable of handling vessels via self-propelled modular transporters (SPMT’s) of nearly 25,000 tons. The new land-level dry-docking facility. Is slated to accommodate up to three large-hulled ships simultaneously, significantly enhancing dry-docking capacity, thereby facilitating seamless maintenance operations and reducing downtime for essential vessels. The project included a dredge design to dredge the basin to a depth of -60 NAVD88 to accommodate operational requirements for the shiplift platform footprint, and 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, which serves as a crucial connection between the land-level facility and the shiplift platform. The project incorporated state-of-the-art equipment and systems for fire suppression, industrial stormwater treatment, and operational support utility systems.

Foth designed all marine and upland structures including support piers, the transfer bridge and bulkhead extension; land-level concrete dry-dock support platform; industrial stormwater systems; and site civil infrastructure including grading, paving and utility systems. Land-level foundation support design was provided by Geopier, a division of CMC; a river water pump-station design by The Vertex Companies; and building architectural/structural including support mechanical, electrical and plumbing systems by EUA. Geotechnical and foundation engineering support was provided by Ardaman & Associates, Inc.

There were complex geological conditions and technical requirements inherent in constructing the marine structures and land-level dry-docking facility. We addressed this by collaborating closely with geotechnical industry experts and the contractor during construction to devise innovative foundation support systems. Utilizing advanced construction techniques and materials, we ensured the structural integrity and stability of the facility. Meticulous planning and proactive risk management strategies were implemented to mitigate potential challenges.

Results

The benefits of this strategic and comprehensive expansion initiative are extensive. By tripling dry-docking maintenance space, BAE Systems is streamlining operational efficiency while minimizing environmental impacts through improved waste containment and pollution reduction measures. The enhanced facility layout will allow for concurrent work on multiple vessels, optimizing resource utilization and maximizing productivity.