Naval Facilities Engineering Command (NAVFAC) Southeast St. Marys, GA, United States

An Ц-led joint venture completed a recapitalization of the Trident Refit Facility (TRF), the largest covered dry dock in North America.

An Ц-led joint venture completed a recapitalization of the Trident Refit Facility (TRF), the largest covered dry dock in North America. Constructed on a secure and active Department of Defense installation, this renovation was one of the largest government investments in naval infrastructure since World War II.

The TRF is one of only two dry docks in the world able to overhaul, modernize and repair strategically loaded U.S. Navy Trident nuclear submarines. The dry dock consists of a reinforced concrete graving structure measuring 700 feet long by 100 feet wide with a depth of 67 feet.

This three-phase project featured rehabilitation and repair of the entire dry dock superstructure, including roof and wall panel replacement, structural rehabilitation and re-coating, and refurbishment and replacement of dry dock waterfront utility systems, including electrical power, mechanical, and telecommunication systems, as well as replacement of the 72,100 gallon per minute auxiliary seawater pumping system. The project also featured extensive concrete repairs, overhaul and repair of a large steel caisson, and replacement of three 90-ton bridge cranes.

Completing the project within a short timeframe was critical to NAVFAC. During the first phase, Ц constructed a contractor “free zone” to eliminate downtime associated with increased site security and help minimize impacts to adjacent shipyard and submarine operations during the next two phases. The multitrade workforce peaked at more than 1,000 and required crews working day and night to meet NAVFAC’s aggressive timeline. Most of the upgrade and rehabilitation work during the second phase was performed in a 15-month closure window.

Key to achieving the Navy’s aggressive schedule was an Ц-designed innovation that maximized workspace within the congested site. Ц self-performed fabrication and installation of four movable elevated work platforms that consisted of 19 steel modules and provided a total elevated surface area of almost two football fields. These platforms, which weighed 380 tons each, rested on the dry dock’s existing crane rails and enabled crews to efficiently repair and recoat the entire dry dock superstructure while concrete repairs and utility upgrades were performed below.