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Civil & Marine

Kings Bay Dry Dock Recapitalization Project

St. Mary's, Georgia

Recapitalization of the Trident Refit Facility (TRF) for nuclear submarines, the largest covered dry dock in North America

Market

Civil & Marine

Key Services

Construction

Preconstruction

Self-Perform

Steel Fabrication

Strategic Partnerships

Virtual Design & Construction

Delivery Method
General Contracting (GC)
Self Perform %
42
Work Hours
3,305,029

The challenge

This project is one of the most mission-critical renovation projects in the modern history of the U.S. Navy and one of DoD’s largest investments in naval infrastructure since World War II. Total scope included overhaul of electrical systems, complete mechanical replacements, significant concrete repair inside the dry dock’s 67-feet-deep basin, steel structural upgrades across the facility and overhaul of two 85-ton bridge cranes. The greatest challenge stemmed from accomplishing all scopes during an immovable 15-month outage. Renovating the Trident Refit Facility (TRF), the largest covered dry dock in North America, required planning for security and worker access. Constructed on an active Department of Defense installation and used for overhauling U.S. Navy Trident nuclear submarines, the project required strict security measures and adherence to naval standards. Completing the extensive renovation within a short timeframe without disrupting adjacent shipyard and submarine operations was critical to NAVFAC.

Key Facts

2023 Best Project, ENR Southeast


31,000 linear feet of weld


1,300 peak work force


15-month closure window

Challenge met

The Alberici-led joint venture tackled the challenge with meticulous planning, innovative solutions, and a large multi-trade workforce. During the first phase, we created a contractor “free zone” to minimize downtime caused by increased site security and to protect adjacent operations. To meet the aggressive schedule, the team utilized an Alberici-designed and fabricated movable work platform measuring roughly 2.2 acres when assembled. It enabled efficient repair and recoating of the dry dock superstructure while conducting concrete repairs and utility upgrades below. Self-performing fabrication and installation of the platform ensured seamless integration and successful completion of the extensive renovation project for the U.S. Navy. Planning commenced in mid-2020 and included procurement of long-lead material and equipment. The Alberici-Mortenson team built temporary structures, developed security and parking processes for up to 1,300 craft employees, and established protocols to navigate unforeseen circumstances during the time-critical second phase, which was completed on-time in September 2022.

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