Sustainable Equipment and Yard Infrastructure Modernization

Overview: Greening the supply chain for shipbuilding isn’t just about what materials go into ships – it’s also about how ships are built and maintained. U.S. shipyards themselves are undergoing a green transformation, upgrading their equipment and infrastructure to reduce energy use and emissions. This includes electrifying machinery that once ran on diesel, modernizing facilities for efficiency, and integrating renewable energy sources on-site. Both private industry and government incentives are driving these changes, yielding shipyards that are cleaner, more energy-efficient, and resilient.

Electrification of Shipyard Equipment

One major push in yard modernization is replacing fossil-fueled equipment with electric or hybrid versions. Traditional shipyards use heavy machinery – cranes, forklifts, welding gear, generators, even vehicles – which often run on diesel fuel. Transitioning these to electric power cuts local pollution and carbon emissions significantly:

• Electric Cranes: Crane operations (for lifting blocks or cargo) are energy-intensive. New pedestal and gantry cranes with electric drives are being installed to replace older diesel-driven models. For example, a shipyard in Oregon launched an electrification project that includes an 18-ton electric crane plus solar power integration to supply it . Electric cranes not only eliminate diesel exhaust but also offer precise control and lower maintenance. Companies like Konecranes and Liebherr now offer high-capacity port and shipyard cranes that plug into the grid or battery packs, proving their viability even for heavy lifts.

• Battery-Electric Vehicles and Carts: The vast facilities of a shipyard require transport – from forklifts moving materials to crew shuttle vans. Leading yards are switching to electric forklifts, utility carts, and work vehicles. Blount Boats (RI) and other builders have invested in electric forklifts and mobile lifts to improve material handling efficiency with zero tailpipe emissions . These swaps have immediate air quality benefits, especially in enclosed fabrication shops. Some yards are also deploying autonomous or remotely operated electric yard tractors to position large modules, reducing the need for diesel tugs.

• Hybrid Drydocks and Pumps: Drydock operations (pumping water in/out, moving caissons) traditionally use large diesel pumps or generators. New drydock designs incorporate hybrid power systems – e.g. electric pumps powered from shore power, with diesel backup only as needed. Fincantieri Bay Shipbuilding in Wisconsin is upgrading graving dock pumps to modern efficient models , likely aiming to cut energy use. Additionally, the concept of floating drydocks with integrated battery storage is emerging: during high power demand (pumping down the dock), they draw from on-board batteries or grid, then recharge during idle times. This smooths out spikes in load and can utilize renewable energy.

• Green Blast & Paint Facilities: Painting and sandblasting typically involve ventilation fans, compressors, and sometimes diesel air handlers. Electric “green” blast and paint booths are being adopted, such as a new installation in Mississippi that received federal funding . These booths use electric motors for air filtration and climate control, capturing paint overspray and solvent fumes with advanced filters. They improve worker health conditions and prevent VOC emissions from escaping. Coupled with solar or renewable power, such facilities drastically shrink the environmental footprint of surface treatment processes.

• Shore Power for Vessels: While not equipment within the yard, providing ships under construction or repair with shore-supplied electricity is another sustainability move. Instead of running onboard diesel generators for power, vessels can plug into the yard’s electric grid (which increasingly may be renewable-powered). Naval shipyards and commercial yards alike have been expanding shore power capacity to reduce emissions during outfitting and repair periods.

These electrification steps are often supported by government grants. The U.S. Maritime Administration (MARAD), for instance, has a Small Shipyard Grant Program that recently funded numerous equipment upgrades with a green angle – from electric cranes and hoists to energy-efficient welding machines . In South Carolina, Detyens Shipyards used grant funds to replace old diesel fire pumps with new electric pumps for pier-side ship support, eliminating a source of routine diesel exhaust . Across the country, dozens of small and mid-sized yards are following suit, proving that electrification is feasible and beneficial even in heavy industries like shipbuilding.

Energy-Efficient Facilities and Yard Infrastructure

Modernizing shipyard infrastructure for sustainability goes beyond swapping equipment; it involves re-engineering how yards consume energy. Many U.S. shipyards are decades old, with energy-hungry lighting, heating, and industrial systems. Retrofitting these with efficient technologies yields significant gains:

• LED Lighting & Smart Controls: High-output LED lights are replacing legacy high-pressure sodium or metal-halide lamps in shipyard bays, drydocks, and yards. The impact is dramatic: at Ingalls Shipbuilding (MS), an LED retrofit project replaced over 16,000 industrial light fixtures, cutting the facility’s lighting power requirement from 4.2 MW to 2.0 MW . Motion sensors and scheduling software ensure lights and ventilation run only when needed. These changes improve visibility for workers and slash electricity usage. Newport News Shipbuilding reported saving 2.5 million kWh annually by deploying LED lighting in new facilities and upgrading existing fixtures, plus another 2.9 million kWh by fixing compressed air leaks in its systems – together reducing both cost and carbon footprint (as noted in HII’s 2022 Sustainability Report).

• Efficient HVAC and Heating: Ship production often requires large enclosed shops (for module construction, painting, etc.) that must be ventilated or heated. Yards are installing high-efficiency HVAC systems, including heat recovery ventilators that capture warmth from exhaust air. Some have transitioned from oil-fired boilers to natural gas or electric heating. Newport News Shipbuilding converted its steam-generating plant from burning heavy fuel oil to cleaner natural gas, eliminating significant particulate and sulfur emissions and improving energy efficiency . Such conversions not only reduce greenhouse gases but also pollutants, aiding local air quality compliance.

• On-Site Power Generation and Microgrids: To improve resilience and use cleaner energy, several shipyards have adopted on-site generation like solar panels, wind turbines, and combined heat-and-power (CHP) plants. For example, a research study found a typical large shipyard could host several megawatts of solar PV on its facility roofs and open areas . Some yards have acted on this: Grandweld Shipyards in Dubai installed 2,000+ solar panels and announced it will meet 100% of its energy needs via solar by 2025 – a model that U.S. yards are studying. Domestically, yards such as Shaver Transportation’s shipyard in Oregon are integrating solar arrays as part of their electrification upgrades . On the public side, the U.S. Navy has pioneered shipyard microgrids – Portsmouth Naval Shipyard (ME) is implementing a $58 million energy resiliency project with a new 7.5 MW cogeneration (CHP) plant and 1 MW battery storage, all tied together with intelligent microgrid controls . This system allows the yard to self-generate much of its power (efficiently using waste heat for heating) and island itself from the grid if needed, ensuring mission continuity with lower overall energy use.

• Green Buildings and Infrastructure: New construction at shipyards (such as offices, warehouses, training facilities) is being done to LEED or equivalent green building standards. This means features like solar reflective roofing, rainwater harvesting, efficient water fixtures, and use of recycled building materials. Some shipyard offices now utilize geothermal heat pumps for climate control or have living vegetative roofs to reduce stormwater runoff. Additionally, yards are upgrading infrastructure like compressed air systems (fixing leaks, using variable speed compressors), and installing energy management systems. Digital twin technology is also emerging as a tool: by simulating the yard’s operations digitally, managers can optimize energy flows and find further efficiencies .

These modernization efforts receive support from various government and private programs. The Department of Defense has run Energy Saving Performance Contracts (ESPCs) at naval shipyards, where companies like Ameresco invest in efficiency upgrades (lighting, power plants, etc.) and get paid from the energy cost savings. The Department of Energy’s industrial assessment programs have also started including shipbuilding in their scope, offering audits and recommendations. Importantly, many measures not only help the environment but reduce operating costs, making yards more competitive. For instance, Ingalls’ massive LED project not only halved power usage but also reduced maintenance (LEDs last longer) and improved safety with better lighting – benefiting the bottom line and workforce.

Integration of Renewable Energy and Clean Power

Shipyards are in a unique position to benefit from renewables due to their large footprint and coastal location:

• Solar Photovoltaics: Expansive rooftops on warehouses and assembly halls are perfect for solar panels. Some U.S. yards have installed PV arrays to directly supply a portion of their electricity. Even a mid-size yard can generate a few hundred kilowatts from rooftop solar. As an example, the Port of Seattle (which includes Fishermen’s Terminal shipyard facilities) put solar panels on pier roofs as a pilot, generating clean power for facility use . Over a year, solar can offset a notable chunk of daytime electricity needs for welding shops or offices.

• Wind and Tidal Energy: Coastal yards in windy regions might explore small wind turbines on-site. While urban or naval shipyards may have restrictions, more remote yards (or those with ample waterfront) could utilize offshore or nearshore wind turbines dedicated to yard power. Additionally, R&D projects in Europe have considered tidal or wave energy devices at shipyard sites (since yards are by the water). These are still experimental, but a pilot could both supply energy and showcase cutting-edge marine technology.

• Energy Storage & Peak Shaving: To manage the intermittent nature of renewables and the variable loads in a shipyard (welding activity peaks, crane operations, etc.), yards are starting to incorporate battery storage systems. Large lithium-ion battery banks or even flow batteries can charge when excess solar or grid power is available (or at night when rates are low), and discharge during peak demand. This evens out the load and ensures a steady supply for critical operations. The Portsmouth Naval Shipyard microgrid mentioned above uses a battery to enhance reliability . In the future, decommissioned EV batteries could even find second-life use as stationary storage for shipyards.

• Clean Energy Purchases: Not every yard can produce all its own power on-site, but they can still green their energy supply by purchasing renewable energy from the grid. Many shipbuilders are enrolling in utility green power programs or leveraging Power Purchase Agreements (PPAs) to source wind/solar energy equivalent to their consumption. This indirectly supports the renewables sector and helps yards hit sustainability targets for scope 2 emissions (purchased electricity).

In sum, the shipyard of the future might generate a significant share of its energy on its own premises and draw the rest from a clean regional grid. A hypothetical modern yard could have solar canopies over parking lots powering EV chargers for employee cars, a wind turbine at the breakwater powering the paint shop, and a battery backup to keep operations running smoothly. Such visions are increasingly within reach as technology costs fall.

Government Incentives and Case Studies

Federal and state initiatives recognize the importance of modernizing maritime infrastructure for both competitiveness and environmental goals. Recent years have seen increased funding and policy support for sustainable shipyard upgrades:

• MARAD Grants: As noted, the Maritime Administration provides grants to small shipyards for capital improvements. In 2023, a significant number of these grants had green elements – funding electric cranes, new solar-equipped facilities, energy-efficient machinery, and other upgrades across dozens of shipyards . These investments collectively improve the industry’s footprint. For example, a yard in New Orleans got a new 60-ton crane, another in New Jersey upgraded an old marine railway slip with modern, efficient systems . While the program’s goal is broadly to boost productivity, MARAD explicitly highlighted how some projects would reduce emissions and energy costs, aligning with sustainability aims.

• Navy Shipyard Modernization: The U.S. Navy’s four public shipyards (Norfolk, Pearl Harbor, Portsmouth, Puget Sound) are undergoing a once-in-a-generation modernization under the Shipyard Infrastructure Optimization Program (SIOP). Embedded in these multi-billion-dollar upgrades are sustainability features: energy-efficient building designs, state-of-the-art equipment, and environmental remediation. At Portsmouth NSY, the Navy’s ESPC project with Ameresco (2020) added not just the CHP and battery system, but also upgraded lighting, HVAC, and industrial processes to save energy . Similarly, Pearl Harbor NSY installed a large solar farm on base to cut grid reliance. These public yard improvements often serve as best-practice examples that private yards can learn from.

• Tax Incentives and Climate Policy: The Inflation Reduction Act (IRA) of 2022 and the Bipartisan Infrastructure Law provide various incentives that shipyards can tap. IRA, for instance, has industrial energy efficiency grants and credits for installing renewable energy or energy storage at manufacturing sites, which could apply to shipyards. There are also tax credits for purchasing heavy electric vehicles and building charging infrastructure – directly relevant if a yard electrifies its trucks and cranes. State programs, like California’s cleantech grants, have even supported a few green maritime projects (e.g. a hydrogen fuel cell tug under construction).

• Case Study – Electric Yard Retrofit: Consider a private Gulf Coast shipyard that embarked on a comprehensive retrofit. They secured a mix of state energy loans and a federal grant to implement changes: replacing all yard lighting with LEDs, purchasing two electric travelift transporters for moving ships, installing a 500 kW solar carport for employee parking, and upgrading old air compressors with high-efficiency models with variable speed drives. The result was a 40% reduction in grid electricity consumption and elimination of tens of thousands of gallons of diesel per year. Workers benefited from quieter, cleaner equipment, and the yard boosted its operational efficiency (the new transporters moved vessels faster and with less downtime). This example illustrates how combining multiple upgrades can yield compounding benefits – the solar generation offset the added electrical load from the new electric machines, and the reduced fuel and power bills helped pay back the investment quickly.

Challenges and Opportunities: Upfront costs and downtime for installation are the main hurdles in infrastructure modernization. However, government incentives and long-term savings are making the business case clearer. Additionally, as environmental regulations tighten (for instance, stricter stormwater and emissions permits), investing in cleaner tech preempts compliance risks. Many shipyard CEOs also note that adopting green practices helps attract a new generation of workers who value sustainability, an important co-benefit in an industry facing skilled labor shortages.

In the coming years, we can expect most U.S. shipyards, big and small, to further incorporate green infrastructure: solar panels glinting on rooftops, battery charging stations buzzing, and electric cranes silently swinging massive ship blocks into place. This evolution not only supports national climate goals but strengthens the supply chain by making ship construction less exposed to fossil fuel price swings and regulatory penalties. A modern, eco-efficient shipyard is ultimately a more productive and resilient one – a key part of sustaining the U.S. maritime industry for decades to come.