Overview
Project Number: S2882
Project Title: Improved Lead Caulking Installation Process
Period of Performance: FEB21 – FEB23
Objective
General Dynamics Electric Boat’s (GDEB’s) current process for lead caulking is time-consuming and labor-intensive. The trades manually locate lead bars / strips into lead bays and use machinery similar to a jackhammer to pound the lead into place, eliminating voids and securing lead sheets within the bay. The intensity of this machinery is identified as a long-term safety concern. The tool exhibits extreme vibrational force, which is hazardous as it is absorbed through the operator’s body, causing injury.
The lead-caulking process is a tedious, physically demanding and unique process that needs to be modernized to support the VIRGINIA Payload Module (VPM) and COLUMBIA Class submarine (CLB) programs. This Naval Shipbuilding and Advanced Manufacturing (NSAM) Center project will improve the lead-caulking installation process for VPM and CLB by developing an improved installation tool that removes or minimizes the lead installer’s exposure to lead and physically intense, time-consuming work.
Benefits/Payoff
Once implemented, GDEB anticipates this project will improve the efficiency of lead-caulking processes and worker safety. Implementation of new technologies / products developed under this project is expected to result in estimated savings of $467.0K per VIRGINIA Class submarine (VCS), $607.0K per VPM and $982.0K per CLB hulls for estimated five-year savings of $8.4M. The solution technology is expected to be implemented at GDEB’s facility in late FY2023.
Implementation
GDEB will implement the solution in a production environment beginning in the fourth quarter of FY2023 on multiple ship platforms, including in the construction of VCS, VPM and CLB.
*Prepared under ONR Contract N00014-19-D-7001 as part of the Navy ManTech Program.
*DISTRIBUTION STATEMENT A. Approved for public release: distribution unlimited. DCN# 0543-545-23