"The most expensive ship built by the Navy" faces a record 11-month deployment plagued by sewage failures, a 30-hour fire, and a displaced crew.
USS Gerald R. Ford (CVN-78) Deployment Timeline & Schedule
The carrier departed Norfolk, Virginia, on June 24, 2024. As of the latest reports, the deployment has exceeded 10 months, setting the record for the longest carrier deployment since the Vietnam War.
The ship is expected to return to Norfolk later this month or in May, bringing the total deployment to approximately 11 months. This far surpasses the standard peacetime deployment length of six months and the Navy's typical aim of six to seven months.
During the deployment, the carrier has operated in Europe, the Caribbean, and the Middle East. It was initially heading for the Mediterranean before being redeployed to the Caribbean in November as part of operations targeting Venezuelan leader Nicolás Maduro and sanctioned oil tankers. The ship subsequently moved to the Middle East, operating off the coast of Israel and in the Red Sea.
Sewage System Failures
The ship's Vacuum Collection, Holding and Transfer (VCHT) system has experienced persistent failures throughout the deployment. According to Navy documents obtained via a Freedom of Information Act (FOIA) request, a trouble call related to the VCHT system has been made daily since June 2023, when the entire crew is present.
The system, adopted in part from the cruise ship industry, was designed without urinals, contributing to higher water usage than anticipated. Issues identified include:
- Blockages caused by foreign objects such as t-shirts, rope, brown paper towels, and commercial toilet paper due to narrow vacuum pipes.
- Loose valves at the back of the toilets leading to a loss of suction in one of 10 zones.
- Calcium build-ups in narrow pipes, particularly in lower decks, representing the most expensive issue.
The General Accountability Office (GAO) reported in 2020 that the system was undersized and poorly designed, estimating a cost of $400,000 for an acid flush to restore the system. The ship has undergone this procedure at least 10 times since 2023, a process that can only be performed in port. An email from the engineering department on March 18, 2025, indicated 205 breakdowns in four days, with sailors responsible for sewage system maintenance working 19 hours a day to manage the demand.
The carrier has requested external assistance 42 times since 2023, with 32 calls occurring in 2025 and 12 during the current deployment. While an average outage duration is reported to be between 30 minutes and two hours, a Fleet Forces Command spokesman stated that the problems have had "no operational impact."
Fire Incident
On March 12, 2025, a fire occurred in the ship's main laundry area.
The fire burned for over 30 hours and injured three sailors, with one requiring airlift for stable condition. Two sailors sustained injuries, and 600 sailors were displaced from their bunks due to the incident. The displaced sailors were required to sleep on tables or the floor.
US Central Command stated that there was no damage to the ship's propulsion plant and that the aircraft carrier remained fully operational following the fire. The electrical system, hot water supply, and plumbing have been fully restored.
The Naval Criminal Investigative Service (NCIS), with assistance from the Bureau of Alcohol, Tobacco, Firearms and Explosives (ATF), is investigating the cause of the fire, including whether it was intentionally set.
Impact on Crew and Families
The prolonged deployment has presented several challenges for the crew. Families have reported delays in receiving packages, with some deliveries taking up to two months. The Armed Services YMCA in Hampton Roads operates a food pantry for military families, which has reduced its hours to two days per week due to high demand. Blue Star Families has opened a chapter in Norfolk to support families during the extended deployment.
Service members receive hardship duty pay of up to $495 per month after 220 days deployed, a rate that has not been updated since 2014.
System History and Future Maintenance
Similar sewage system issues were experienced on the USS George H.W. Bush, which underwent an overhaul in 2015. The USS Ford is scheduled for a maintenance overhaul at Norfolk Naval Shipyard upon its return, expected to include similar upgrades.
The delayed delivery of the next aircraft carrier, USS John F. Kennedy (now scheduled for 2027), has increased pressure on existing carriers like the Ford. The USS Ford was the most expensive ship built by the Navy, incorporating unproven new technologies that contributed to increased costs and delayed delivery.