Project Number: S2933

Project Title: One Sided Deck Tie-Down Welding and Inspection

Period of Performance: JAN23 – MAR25

All navy ships currently built at Ingalls require the installation of aircraft tie downs on the deck that have to be structurally welded on both sides. This is a labor-intensive process and if defects are found during the process the deck panel assembly has to be flipped multiple times for re-work and re-inspection.

The objective of this project is to increase efficiencies in the aircraft tie-down and heavy weather tie-down installation process by structurally welding the tie-downs from one side on DDG, LHA and LPD versus the current process of structurally welding the tie-downs from both sides. This project will focus on performing the required testing and obtaining NAVSEA tech warrant approval to weld and inspect aircraft and heavy weather tie-downs from one side with the use of a permanent backing bar. This would eliminate the need for back gouging and welding the opposite side as well as eliminate the magnetic particle testing (MT) inspection on the opposite side and flipping the panel multiple times.

This effort will be accomplished in two phases over a 26-month period. Phase I will consist of requirements definition and test plan development. Phase II will perform one sided deck tie-down welding tests and functionality demonstrations.

By structurally welding deck tie-downs from only one side, the initial estimate for 5-year cost savings is $2.9M for all Ingalls platforms and $1.3M for DDG, which equates to an ROI of 1.83 and 0.33 respectively.

The results of this project will be implemented at Ingalls in support of multiple ship platforms, including the construction of LHA-10, LPD 32,33,34 and DDG 141,143,147,149 in the second quarter of fiscal year 2026. Preliminary plans indicate that full implementation of the equipment and methods will occur within 12 months of project completion.