This design flaw in the new US warship is costing the US Navy dearly

The United States Navy is grappling with serious challenges in its new frigate program. According to a recent report by the Government Accountability Office (GAO), the USS Constellation-class ships are significantly heavier than anticipated, leading to major construction delays.

Published in June, the GAO report reveals that the ships are 759 tons heavier than expected—a 13% increase over the original projections. Construction of the first ship in the class began just over two years ago, yet progress has reached only 10% so far.

As a result, the delivery timeline has slipped by three years. Originally slated for completion in 2026, the program is now delayed until at least 2029. Compounding the issue, the frigate’s design remains incomplete, raising concerns that further delays may be unavoidable.

The initial design for the USS Constellation class was modelled closely on the French-Italian FREMM ships, sharing approximately 85% of the original structure. However, due to numerous structural and technical modifications requested by the Navy, only 15% of the current design remains faithful to that model. These modifications have led to increased size and weight.

The shipbuilder, Marinette Marine, is now exploring ways to reduce the ship’s weight without compromising the Navy’s evolving requirements.

Calls for accountability and debate over future

The GAO report criticises the Navy for launching the project without a finalised design. Meanwhile, some members of Congress have pointed to the Navy’s inability to maintain “stable requirements” as a key issue. As a result, debate continues over whether the project can still be salvaged—or whether it’s time to scrap it altogether.

“The question is whether we’re at a point where we can recover quickly and get back on track, stay on schedule and on budget,” said Rep. Rob Wittman (R-Va.) at the Navy League’s Sea-Air-Space 2025 panel in April. “I don’t know if you could adjust the schedule, or if you’re saying maybe we’ve gone too far and we need to go in a different direction. The Navy is going to have to ask that question now. It can’t put it off.”

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These developments underscore the broader challenges facing the U.S. naval industry—particularly as it confronts growing competition from one of its primary global rivals: China.

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