Editor’s note: This report has been updated to include a statement from HII.
Navy leaders this week identified an aircraft carrier and two submarines affected by faulty weld issues during work at the Newport News Shipyard in Virginia, but say that the substandard work did not take place on components that affect ship safety or operations.
In a letter to House and Senate armed services committee members Thursday, Navy Secretary Carlos Del Toro said impacted ships include the recently-revamped aircraft carrier George Washington and the brand-new attack submarines Hyman G. Rickover and New Jersey.
Citing shipyard officials, Del Toro wrote that the issue involved “welders who did not follow welding procedures properly.”
“Importantly, the Naval Sea Systems Command (NAVSEA) has assessed that the welds were not on components or systems that affect ship safety or operations,” he wrote. “NAVSEA, as the technical warrant holder, has determined the ships are safe to operate.”
Del Toro wrote that he first became aware of the issue on Sept. 24.
The Navy had identified those three vessels as having been impacted as of Thursday, and Del Toro’s memo states that the sea service is examining welds on 23 ships under construction or in maintenance to see if faulty welds there may impact future operations.
Lawmakers demand answers over reports of faulty Navy ship welding
Last week, officials with HII, the company that owns Newport News Shipbuilding, acknowledged that “some welders knowingly circumvented certain welding procedures” while working on military vessels.
“Malicious intent” was ruled out as a the source of the problem, HII said in a statement.
“Upon discovery of some welders not consistently following procedures, we followed our protocol, took action to communicate with our customers and regulators in a timely manner and began working the issue with the Navy,” the company said in an additional statement Friday.
The Department of Justice is investigating the matter, lawmakers confirmed this week.
Del Toro promised to cooperate with that probe and wrote Thursday that the Navy “is evaluating all legal options, and reserving our rights accordingly.”
Congressional leaders have pushed the Navy this week for more answers on the scope of the problem and how it was allowed to happen.
“These vessels are critical to U.S. defense,” House Armed Services Committee members wrote to Del Toro this week. “We must ensure that these vessels are protected against any bad actors seeking to put U.S. national security or our service members at risk.”
The Newport News yard is one of two in the United States focused on the nuclear fleet. The yard constructs parts of several submarine classes, as well as Ford-class aircraft carriers.
While the timeframe of the faulty welds has not been disclosed, George Washington left the Newport News yard in May 2023 following its midlife maintenance overhaul that began in 2017 and was originally supposed to wrap in 2021. Officials blamed the delays on extra unanticipated work during the so-called refueling and complex overhaul, or RCOH.
The carrier is currently underway in the Pacific Ocean and on its way to its new home port in Japan.
The submarine Hyman G. Rickover was commissioned in October 2023, while New Jersey was just commissioned on Sept. 14.
In the memo, Del Toro promised a full review of operations at the shipyard to ensure the welding problems do not occur again.
“The safety of our sailors and ships is of paramount importance,” he wrote. “We have given top priority to the task of defining and examining the scope of improper welds conducted on operational in-service ships, and I have directed my Navy technical experts to co-locate with the shipyard immediately to support a thorough review.”
