Modular Access System with Bridging Creates Safe Dock-to-Ship Connection in Critical Navy Refit
In a bold milestone for American naval operations, the USS The Sullivans (DDG 68), a 505-foot, 7,100-ton Arleigh Burke–class destroyer, was successfully drydocked at the BAE Systems Jacksonville Ship Repair Facility using a 25,000-ton shiplift system. The historic lift marks the first time a destroyer of this class has been docked using this method and signals a new era in U.S. Navy ship maintenance.
But while the headlines focus on what happened below the ship, what made the work possible above was just as critical.
To safely and efficiently move hundreds of personnel between the dock and the ship’s entry points, SafeSmart Access deployed a Z-Stack modular stair tower system, complete with a custom bridging platform. Together, these elements formed a secure, OSHA-compliant access corridor, connecting drydock ground level to the ship’s deck without the need for scaffold or permanent fixtures.
Drydock Access Reimagined
Shipyards have long relied on scaffold towers or gangways to manage movement between dock and vessel, but both approaches come with limitations: time-consuming setup, inflexibility, and potential safety hazards in high-traffic areas.
For this critical U.S. Navy vessel, SafeSmart’s Z-Stack provided a complete modular access solution, from the dock floor, up the stair tower, and across the bridging platform to the vessel itself. The system was deployed quickly after the drydock lift, creating an immediate safe pathway for maintenance crews to begin their work.
The Z-Stack system ensured:
Uninterrupted crew movement from dock to ship
Stable, anti-slip surfaces throughout the full access route
Compliant fall protection across all transition points
Elimination of ladder use, scaffold builds, or unsafe improvisations
Safety Meets Speed in a Complex Setting
This drydock operation was part of a larger initiative to extend the life of the USS The Sullivans, which is scheduled to return to active duty in spring 2027. With multiple trade crews working on hull prep, structural retrofits, systems upgrades, and inspections, the movement of personnel and tools is constant.
Having the Z-Stack + bridging system in place from day one enabled:
Faster crew mobilization
Fewer delays from reconfiguring access points
Safer transitions in wet, shifting dock conditions
A cleaner, more professional workspace in a mission-critical setting
Ready to learn more about z-stack?
Whether you’re in defense, shipbuilding, or industrial drydock operations, SafeSmart can help you streamline movement, improve safety, and eliminate scaffolding delays with Z-Stack.
