Upgrades Extend Service Life of Dry Dock No. 1 at Naval Base San Diego

Recognizing the limitations to dry dock operations posed by its configuration, the Navy identified several upgrades to modernize Dry Dock No. 1 to meet current and future demands and prolong its service life in support of its mission to ensure freedom of the seas.

Dry Dock No. 1 was built at Naval Base San Diego in 1942 during World War II with a configuration to meet the requirements of the naval fleet at that time. In the 80 years since, the Navy has undergone many fleet upgrades, while Dry Dock No. 1 has remained largely the same. 

In 2016, the USS Howard, a DDG-51 class vessel, was docked at Naval Base San Diego requiring emergency repairs to its shaft and supporting equipment. Although Dry Dock No. 1 was available, the berth could not accommodate a DDG-51 class vessel because of its sonar dome. This identified an urgent need for a dock that could accommodate these vessel types.

The Navy, through a $125 million Naval Facilities Engineering Systems Command Indefinite Delivery, Indefinite Quantity contract, awarded a task order to identify modifications to the dry dock that would allow it to accept DDG-51 class vessels that are equipped with a sonar dome under its keel. 

The project had four main components, each with its own unique set of challenges: a retrofit design of mechanical systems; dredge design for the access channel and turning basin; construction of a new in-haul rail system; and construction of a new sonar dome pit on the floor of the dry dock. 

The GHD-COWI Joint Venture (JV) was awarded the task order to identify the dry dock modifications. The modifications would require repairing some of the dry dock floor and avoiding retrofitting the entire dry dock. Other repairs were identified to be made as well, including the replacement of dewatering pumps that were beyond their operation life. 

The team modernized the dry dock structure using an innovative micro-pile system approach that avoided the need for dewatering to accommodate DDG-51 class vessels. This was achieved by deepening only a portion of the dry dock floor, significantly decreasing construction time and cost. Along with updates to the dry dock floor, a trolley-based in-haul rail system was added to the basin to simplify training and maintenance, provide more precise control of vessels during the docking process, and eliminate human error caused by traditional walking lines. 

Large-scale refurbishment of the dewatering pumps, which had not been overhauled in more than 45 years, was also conducted. When it was discovered that the replacement pumps were no longer manufactured in the US, the team worked with domestic suppliers to custom-build the required 800-horsepower axial flow pumps. Control systems were also upgraded as part of this modernization project. 

The JV team collaborated closely with the Navy to develop outside-the-box engineering solutions to overcome challenges that could be replicated for other facilities going forward. 

After upgrading the facility, its life expectancy, performance and reliability have improved and been extended by decades. The dry dock can now accommodate DDG-51 class vessels, and the added in-haul system makes docking faster, more precise and consistent.  

As the Navy continues to invest in shipyard modernization in support of its mission to ensure freedom of the seas,    lessons learned from the renovation at Naval Base San Diego can play an important role in the long-term stability of fleet operations.

Read more about the lessons learned from this renovation in the Society of American Military Engineer’s publication, The Military Engineer: Modernizing Dry Dock No. 1 at Naval Base San Diego.