Project Number: S2915

Project Title: Lead Ladle Replacement

Period of Performance: AUG21 – APR25

Molten lead is poured in place into numerous structural bays within a nuclear submarine for multiple functionalities. This requires a person to manipulate a ladle, loaded with 50 lbs. of molten lead and traverse the stiffened structure to pour it where needed. Each bay requires 30 to 40 ladles of lead. This is an awkward, tiring and hazardous operation. Approximately 14,500 lbs. per VIRGINIA Class submarine (VCS) and 8,000 lbs. per COLUMBIA Class submarine (CLB) of lead are poured in place. General Dynamics Electric Boat (GDEB) employees first place ingots of lead and then pour molten lead to fill cracks and crevices between the ingots.
The objective of this Center for Naval Metalworking (CNM) project is to find a system that will allow for the continued safe delivery of molten lead across the structure to a designated space without the use of a ladle. This will reduce the time it takes to pour molten lead into the structural bays. An additional benefit is the reduction of injury to personnel by reducing the repetitive motion required to lift, transport and pour the molten lead.

If the project achieves its threshold labor reduction goal, GDEB anticipates estimated savings of $168.0K per VIRGINIA Payload Module (VPM) hull and $168.0K savings per CLB hull. This is expected to create total five-year savings of $2.1M.

Upon successful and timely completion of the Lead Ladle Replacement ManTech project and acceptance of both the technology and associated business case by the acquisition Program Offices, the results will transition to the GDEB facility. GDEB anticipates implementation in the third quarter of FY2024. The estimated first hull of implementation will be SSN827 for CLB and SSN811 for VCS.