The U.S. Navy’s most advanced warships — the USS Gerald R. Ford and USS Zumwalt, among them — are paradoxically more vulnerable to fire than older ships. The USS Zumwalt operates a Total Ship Computing Environment with more than 6 million lines of code, with wiring that runs through compartments exposed to ocean salt and high humidity. The USS Gerald R. Ford uses electromagnetic aircraft launch systems running at extremely high voltages and currents — generating significant heat. Both ships use integrated power systems that distribute electricity for propulsion and weapons together. Reduced crew sizes through automation mean fewer hands to respond when something catches fire. Fuel, lubricants, and ammunition all share confined shipboard spaces.
The U.S. Navy and Fire: A Problem That Isn’t Easy to Solve
The Arleigh Burke-class guided-missile destroyer USS Lassen (DDG 82) moves into position for an underway exercise with the British Royal Navy aircraft carrier HMS Queen Elizabeth (R08) and Pre-Commissioning Unit (PCU) Michael Monsoor (DDG 1001). The future USS Michael Monsoor is the second ship in the Zumwalt-class of guided-missile destroyers. (Photo by Mass Communication Specialist 1st Class John Philip Wagner, Jr./Released)
Massive amounts of electrical power, heat generation, and controlled “mini-explosions” of fighter-jet take off are just a few of the reasons why aircraft carriers and advanced warships operate with an extremely serious risk of fire. Fires aboard U.S. Navy warships are among the most dangerous non-combat threats sailors face at sea.
Even on cutting-edge vessels like the USS Gerald R. Ford and the USS Zumwalt, the risk of fire remains ever-present.
These ships feature new generations of warship technologies, including advanced propulsion systems, powerful electrical networks, and extensive computer automation.
Yet, in a somewhat paradoxical fashion, their sophistication does not eliminate risk but rather increases their vulnerability. Fires aboard such warships typically result from a complex mix of factors, including mechanical failures, electrical hazards, environmental conditions, human factors, and the ongoing risk of explosions.
The highest risks on ships such as the USS Zumwalt or USS Ford likely relate to their advanced technologies.
For instance, the USS Zumwalt uses an integrated power system that generates and distributes electricity for nearly all onboard functions, from propulsion to weapons.
The US Navy’s troubled Zumwalt-class destroyers are being revitalized with the integration of Conventional Prompt Strike (CPS) hypersonic missiles, transforming them into powerful long-range strike platforms. The original class of 32 ships was cut to just three after its Advanced Gun System failed due to exorbitant costs. Now, these stealthy, $8 billion warships are having their defunct guns replaced with vertical launch tubes for hypersonic weapons. This upgrade will dramatically increase their strike range from a mere 63 miles to over 1,700 miles, making the Zumwalts relevant and formidable assets for deterring adversaries like China in the 21st century.
Most of the technologies on board the USS Zumwalt rely on computing and electrical wiring; the ship operates the Total Ship Computing Environment, an advanced, high-speed, expansive computer system engineered with more than six million lines of code.
The more wiring there is, naturally, the higher the risk of fires on board, and consistent exposure to harsh ocean conditions and salt water can also lead to the erosion of wiring on the ship.
Electrical Technologies
The Ford relies on advanced technologies such as electromagnetic aircraft launch systems and high-capacity electrical grids. These systems operate at extremely high voltages and currents, which can generate significant heat.
If components such as cables, transformers, or circuit breakers fail or degrade, they can overheat or spark, potentially igniting nearby materials.
Another major contributor to fire risk is the presence of flammable materials throughout a warship.
Fuel for aircraft and helicopters, lubricants for machinery, hydraulic fluids, and various cleaning chemicals are all necessary for operations, but can ignite under the right conditions.
Ammunition and explosives also present hazards if exposed to heat or flame. In confined shipboard spaces, a small fire can quickly spread if it reaches these materials.
Zumwalt-Class U.S. Navy. Image Credit: Creative Commons.
The Human Factor
Human factors also play a significant role. Despite the advanced automation found on ships like the Ford and Zumwalt, sailors remain responsible for operating, monitoring, and maintaining equipment.
While the USS Ford relies upon new levels of computer automation, much of the ship still relies entirely upon human skill and judgment. Human variables are, of course, influenced by stress, fatigue, or emotional fluctuation.
Errors in judgment, lapses in attention, or deviations from established procedures can all contribute to fire incidents. Fatigue and sleep deprivation are also major concerns; sailors often work long hours in demanding conditions and stand watch for hours at a time, both of which can impair decision-making and increase the likelihood of mistakes.
Design trade-offs in modern warships can also influence fire risk. Advanced ships prioritize stealth, efficiency, and automation, which can sometimes result in reduced crew sizes.
The aircraft carrier USS Gerald R. Ford (CVN 78) successfully completes the third and final scheduled explosive event of Full Ship Shock Trials while underway in the Atlantic Ocean, Aug. 8, 2021. The U.S. Navy conducts shock trials of new ship designs using live explosives to confirm that our warships can continue to meet demanding mission requirements under harsh conditions they might encounter in battle. (U.S. Navy photo by Mass Communication Specialist 3rd Class Novalee Manzella)
While automation can enhance performance and reduce human workload, fewer personnel may mean fewer hands available to respond to emergencies immediately. Additionally, innovative layouts and materials, while beneficial for operational effectiveness, may behave differently under fire conditions compared to traditional designs. Engineers must carefully balance these factors to ensure that safety is not compromised.
Despite these risks, the U.S. Navy places enormous emphasis on fire prevention and response. Ships are equipped with sophisticated detection systems, including heat sensors, smoke detectors, and automated alarms. Fire suppression systems—ranging from sprinklers to specialized foam and gas-based extinguishing agents—are designed to quickly contain outbreaks.
The fire on board the USS Ford, for example, was eventually contained, yet its existence points to the human and mechanical stresses that can be placed on a ship during extended wartime deployment.
About the Author: Kris Osborn
Kris Osborn is a Military Technology Editor. Osborn is also President of Warrior Maven – Center for Military Modernization. Osborn previously served at the Pentagon as a highly qualified expert in the Office of the Assistant Secretary of the Army—Acquisition, Logistics & Technology. Osborn has also worked as an anchor and on-air military specialist at national TV networks. He has appeared as a guest military expert on Fox News, MSNBC, The Military Channel, and The History Channel. He also has a Master’s Degree in Comparative Literature from Columbia University.
