The USS Gerald R. Ford, the US Navy’s most expensive aircraft carrier, has come under renewed scrutiny after it was forced to leave its deployment in the Middle East following a fire on board, even as long-standing concerns about its operational readiness remain unresolved.The carrier arrived at port on the island of Crete earlier this week after a fire broke out in the laundry area during a deployment related to operations related to Iran. The incident injured two sailors and led to more than 200 sailors being treated for smoke inhalation, according to U.S. Sen. Tim Kaine, who raised the issue in a letter to Navy Secretary John Phelan, Bloomberg reported.
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The development has drawn attention to broader questions surrounding the $13.2 billion warship, which was delivered in May 2017 after delays and has since faced ongoing technical and testing challenges.
Lack of operational data
A recent assessment by the Pentagon’s Test Office noted that “insufficient data are available at this time” to determine the operational effectiveness of the Ford-class aircraft carriers, noting that real-world combat tests are not completed even after years of operation.
The report cited by Bloomberg also noted gaps in the “operational suitability” assessment, including the reliability of key systems such as aircraft launch and recovery, radar performance, weapons elevators, and the ship’s ability to continue operations under enemy attack.
The lack of sufficient test data means that it remains unclear how effective an aircraft carrier will be at detecting, tracking or intercepting threats such as enemy aircraft, anti-ship missiles or small attack craft, especially under the pressure of sustained combat operations involving sustained aviation activity.Some previously identified issues also remain unresolved. While the Navy has developed fixes for some of the combat system’s deficiencies highlighted in previous classified assessments, the Pentagon’s testing office said “fixes remain largely unfunded.”
Old sewage problem
The supercarrier also experienced constant sanitation system failure even during active deployment. The carrier introduced a vacuum-based waste system adapted from cruise ships to reduce water use. However, reports, including those cited by Gulf News, indicate that the system’s narrow pipes struggled to handle waste generated by a crew of more than 4,600 sailors, leading to frequent blockages and frequent vacuum failures.
NPR reported that emails it reviewed documented 205 wastewater-related failures over a four-day period, with engineering crews working extended shifts of up to 19 hours to manage leaks and flooding. During its 2025 deployment, the carrier received an average of nearly one sanitation-related maintenance call per day, according to the Navy Times. Previous reports, including one from Forbes in 2022, indicated that severe clogs require specialized acid cleaning procedures that cost about $400,000 each time, reflecting the recurring and expensive nature of the problem.
Extended missions and lack of amenities
The report also cited logistical and personal challenges, including a shortage of berthing space. She noted that an additional 159 beds were needed to adequately accommodate the ship’s crew and associated personnel, warning that such a shortage would “affect the quality of life on board.” The problem could worsen with the addition of newer aircraft and drone systems. Despite these concerns, the Navy confirmed that the carrier continues to demonstrate its operational capabilities.
Its evaluations take into account both test performance and real-world deployments, it said, adding that operations to date have demonstrated the ship’s ability to meet mission requirements while “continuing to improve.”The Ford was deployed at sea for approximately nine months, exceeding the typical deployment cycle of seven months, after participating in operations related to Venezuela before being sent to the Middle East on orders from US President Donald Trump. Senator Kaine said the expanded deployment requires sailors to “improvise with disabled equipment and ship support systems,” and warned it could become the longest aircraft carrier deployment since the end of the Vietnam War.The Navy said it will continue testing and making improvements based on ongoing evaluations and operational experience, noting that evaluation of complex systems like the Ford-class aircraft carriers continues beyond initial deployment.(With inputs from agencies)
