Improving Aircraft Carrier Undocking Operations at Newport News Shipbuilding
Introduction
Based on a presentation by Dock Master John Anderson and Naval Architect AJ Bierbauer at the International Docking Conference.
Challenges with the Traditional Method
The previous process relied on estimated weight changes from work packages, authorized drawings, and reports from shipboard personnel and trades.
Several problems emerged:
- Weight changes were not always reported accurately.
- Drawings did not always reflect completed work.
- Significant labor was required to track weight additions and removals.
- The process provided limited ability to correct vessel list during flooding.
Most importantly, the carrier could not effectively adjust its side-to-side balance during critical phases of the undocking evolution.
Developing a New Approach
To address these issues, Newport News Shipbuilding developed a revised process based on operational experience and historical undocking data.
The new method eliminated:
- Daily weight reporting requirements
- Extensive ballast-control calculations
- Dependence on estimated work-completion percentages
Instead, proven historical data became the baseline for undocking calculations.
Technical Improvements
The revised process introduced direct measurement of vessel list during flooding.
Calibrated micrometer levels and transits monitored the carrier’s position accurately, while transporters carrying test weights were strategically positioned on the flight deck to adjust list and trim as needed.
When the water level reached about 28 feet, flooding operations slowed or paused temporarily to allow precise measurements and corrective actions.
This allowed the dockmaster to monitor vessel behavior in real time and make adjustments before the undocking evolution continued.
Results
The revised procedure delivered several important benefits:
- Reduced labor associated with weight tracking.
- Improved confidence in undocking calculations.
- Increased control of vessel list during flooding.
- Enhanced safety during critical stages of undocking.
- Reduced dependence on potentially inaccurate weight reports.
Most importantly, dockmasters could actively manage vessel stability throughout the evolution rather than relying solely on pre-undocking calculations.
Lessons Learned
The Newport News approach showed that directly measuring vessel condition can often be more effective than tracking thousands of individual weight changes over a long maintenance period.
By combining historical data, precise instrumentation, and real-time observations, the shipyard developed a safer and more efficient undocking process for aircraft carriers.
Conclusion
The Newport News carrier undocking program shows how process improvements can significantly improve both safety and efficiency. By replacing labor-intensive weight tracking with real-time measurements and proven historical data, the shipyard gave dockmasters greater control during one of the most critical phases of dry-dock operations.
The project is an excellent example of how practical operational experience and engineering judgment can improve long-established shipyard procedures.