USS Gerald R. Ford Undergoes Extended Deployment Amid Operational Challenges

The USS Gerald R. Ford, the United States' newest and most expensive aircraft carrier, is facing an extended deployment marked by significant operational challenges, including persistent issues with its vacuum sewage system and a recent fire incident. The $13 billion carrier, which departed in June, is now anticipated to remain at sea until May, potentially making it one of the longest recent carrier deployments. The 4,600 sailors on board have been directly affected by these operational hurdles.

The USS Gerald R. Ford's deployment, potentially lasting a full year, is double the typical length for peacetime operations and has been plagued by an undersized sewage system and a recent 30-hour fire.

The Extended Deployment: A Record-Breaking Mission

The USS Gerald R. Ford departed Norfolk, Virginia, on June 24. As of recent reports, the carrier had already been at sea for 266 days. It is on track to surpass the 321-day deployment record set by the USS Nimitz in 2021. Its return is not expected until May, which would result in approximately a full year at sea—double the typical length of six to seven months for peacetime aircraft carrier deployments.

The carrier's operational path reflects its demanding mission:

• An initial deployment to the Mediterranean.
• Redeployment to the Caribbean in November for operations targeting Venezuelan leader Nicolás Maduro and sanctioned oil tankers.
• Movement to the Middle East, operating off the coast of Israel in the Eastern Mediterranean.
• Subsequent operations in the Red Sea for U.S.-Israeli engagements.

Chairman of the Joint Chiefs of Staff Gen. Dan Caine has acknowledged the extended mission, underscoring its strategic importance.

Persistent Operational Challenges

The prolonged deployment has coincided with multiple reported operational issues, raising concerns about the vessel's systems and crew welfare.

Vacuum Sewage System Failures

The ship's Vacuum Collection, Holding and Transfer (VCHT) system has experienced ongoing failures, leading to an average of one maintenance call per day.

• The General Accountability Office (GAO) reported in 2020 that the system was undersized and poorly designed. Adopted from the cruise ship industry for its water efficiency, the system was designed without urinals, reportedly contributing to higher water usage than anticipated.
• Problems with the VCHT system have been reported since the carrier's initial deployment in 2023, with increasing frequency.
• Navy documents obtained via a Freedom of Information Act (FOIA) request indicate a daily trouble call related to the VCHT system since June 2023 when the entire crew is present.
• The carrier has requested external assistance 42 times since 2023, with 32 calls occurring in 2025 and 12 during the current deployment which began in June.
• An email from the engineering department on March 18, 2025, indicated 205 breakdowns in four days, stating that hull maintenance technicians (HTs) were working 19 hours a day to manage the demand.
• In February, the aircraft carrier reportedly experienced a blockage affecting approximately 650 toilets on board.

Identified issues contributing to these failures include:

• Blockages caused by foreign objects such as t-shirts, rope, brown paper towels, and commercial toilet paper due to narrow vacuum pipes.
• A common problem involves a valve at the back of the toilets becoming loose, leading to a loss of suction in one of 10 zones.
• Calcium build-ups in narrow pipes, particularly in lower decks, are a significant issue. The 2020 GAO report estimated 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; it can only be performed in port.

The Navy has acknowledged VCHT system issues for over a decade. A similar vacuum system on the USS George H.W. Bush, a Nimitz-Class carrier, experienced comparable problems in 2013 and underwent an overhaul in 2015 to address them. 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 Board

A fire occurred in the ship's main laundry area on March 12, burning for over 30 hours while the carrier was engaged in military operations.

• Two American sailors sustained injuries, with one requiring airlift for stable condition.
• The incident displaced more than 600 sailors from their berths, requiring them to sleep on tables or the floor, according to The New York Times.
• 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.

Impact on Crew and Vessel

The extended deployment and operational issues have taken a toll. Crew members and their families have expressed concerns regarding morale, particularly following extensions to the deployment schedule.

Extended deployments can lead to crew fatigue, increased workload due to declining sailor numbers, and the potential for deferred scheduled maintenance for the vessel. Senator Mark Warner (D-Va.) expressed concern about the mission's rationale given the extended deployment and onboard issues. Chief of Naval Operations Adml. Daryl Caudle had previously stated he did not wish to see the USS Ford extended, citing impacts on crew, families, and ship wear, but later affirmed the carrier's readiness.

The Road Ahead: History and Future Fixes

The USS Gerald R. Ford was noted as the Navy's most expensive ship, incorporating unproven new technologies that contributed to increased costs and delayed delivery.

The carrier is scheduled for a maintenance overhaul at Norfolk Naval Shipyard upon its return. This overhaul is expected to include VCHT system improvements, similar to upgrades performed on the USS George H.W. Bush (CVN 77) that reportedly led to fewer maintenance problems. 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.

Experts suggest a long-term fix for the VCHT system is not anticipated within the current year. Bryan Clark of the Hudson Institute commented that adopting a sewage system from commercial cruise ships for a nuclear-powered warship, designed for months at sea, might have been a design error.

Chinese military affairs expert Wang Yunfei noted that fires on modern warships are challenging due to complex electrical systems and fuel lines, enclosed internal spaces, and connected ventilation systems that can accelerate flame spread. He suggested that if a fire is not quickly contained, it could indicate issues with automatic extinguisher systems or damage-control training and execution. Wang also stated that if a fire forces a significant number of crew members from their living spaces, it may point to weaknesses in fire-containment design and that prolonged deployments can lead to crew fatigue, potentially reducing emergency response capabilities.