Economic Solutions for New Vessel Construction at Shipyard

After years of focusing on vessel repair, Todd Pacific Shipyards (Todd) in Seattle, WA determined that new vessel construction could again become an economically viable portion of their business model. However, Todd was faced with the reality of an aging shipway which was no longer adequate for modern vessel construction of the magnitude Todd was planning to undertake. Furthermore, repair or complete replacement of the shipway was not economically feasible. As a result, Todd was presented with the challenge of developing economical infrastructure and new procedures for constructing and launching new vessels. The answer to this challenge was a new Level Launch Transfer Facility (LLTF). The new LLTF pier is situated adjacent to the shipyard's existing steel fabrication hall, Building T72, on the West Duwamish Waterway in Seattle. The building itself and the newly constructed LLTF pier make up the facility infrastructure improvements known jointly as the LLTF. The facility was designed to allow construction of new vessel hulls within the fabrication hall, providing a weather protected environment on level ground. Once hull construction is complete, the new ship hulls are moved out of the building, across the new LLTF pier, and onto an awaiting floating drydock that has been moored to the LLTF pier. This transfer operation is currently completed using heavy lift crawlers, and due to the time involved, needs to be carefully coordinated with tides, weather, and the busy Duwamish Waterway vessel traffic. The vessel hulls can then be outfitted with superstructure within the drydock while the drydock is moored adjacent to one of the other available Todd piers. Construction permitting of the new LLTF pier fell within a CERCLA exemption held by Todd as part of a larger Superfund Cleanup Project. An expedited project schedule was based on the deadline for the expiration of the CERCLA exemption, an upcoming fish window period, and Todd awaiting final notification of award on an upcoming new vessel construction contract that would provide the impetus and a portion of the initial capital funding for the facility. This expedited schedule ultimately resulted in the simultaneous construction of the first new vessel and the pier itself such that the construction of the pier was completed approximately 60 days prior to the first vessel launch. This paper will discuss the planning, design, and construction of this new facility; a facility that provided a solution to the important operational challenges faced by Todd in construction of new vessels. It will also discuss the substantial scheduling challenges of design and construction and how those challenges were overcome to provide as-needed facility development which allowed for efficient and economical use of Todd's capital improvement budget. This was achieved through sound planning and strong relationships between Todd, the consultant, and the contractor.