One of the greatest challenges in starship construction is the environment in which it will occur. Starships are normally constructed in orbit (some in deep space) at one of many Federation shipyards. Most shipyards are in open space, consisting of dry-docks and slipways that are nothing more than elaborate rectangular frameworks with sophisticated mechanism for heavy construction. A few shipyards, notably the great San Francisco Spacedock, are massive orbital facilities that enclose zero-G, zero atmosphere environment. In open space, working conditions are extremely hazardous; so elaborate safety measures are used to ensure worker safety. Why build under such conditions? One reason that construction is done under such conditions is the benefit of Zero gravity (or null gravity or neutral orbital gravity). Starships and their components are massive, they can mass up to many thousands (even millions) of tons. Under gravity, many would sag under their own mass. It would also be impractical to have to lift them into orbit from a planet-side shipyard. Another consideration for free-space construction is the acclimation of the structural materials to the vacuum of space for which it will normally occupy. Such variables in temperature and radiation can actually cause changes in dimension to structural components, causing pieces not to fit under proper conditions. If an assembly were constructed under normal gravity and at room temperature, it would become structurally unsound in the vacuum of space. Considerations in metallurgy, unions of dissimilar materials and structural engineering in zero-atmosphere all become primary factors for free space construction. Actual construction begins in the center of the future starship and progress outward to where the hull plates will be attached. Some of the first components for the future starship to be assembled in the shipyard are massive structural trusses that form the skeletal structure. These trusses come in a bewildering variety of shapes and sizes, manufactured at huge free space solar furnaces and delivered to the shipyard by tugs or large transport containers. Many of these trusses are hundreds of meters long and mass upwards of several hundred tons or more. The trusses and other frame-members are positioned by precision shipyard tractor-beams or by construction drones or utility shuttles. Construction work is handled by shipyard workers in special construction EVA suits and by specialized drones and single-man or multi-man utility shuttles (similar to the Starfleet Workbee, customized during their assembly for shipyard work).

As the framework is positioned, specialized welding teams move in and begin the laborious process of fastening the frame-members and trusses to one another. Wearing highly specialized welding EVA suits and employing such equipment as gamma welders, plasma cutters, phaser torches and portable transporter matrix mixers, these teams must carefully join each member to its partner in tolerances measured in microns. As the joints are completed, sensors and leads for the sensors are attached and other specialized equipment (such as SDF and IDF emitters) are installed. Workers cut access ports and utility channels into the framework at specific points and to strict tolerances for this and other equipment to be installed later. As the trusses are assembled, cross-members, stiffeners, connectors, and reinforcing members are attached, according to design to strengthen the super structure, and several major assemblies are readied for installation. Among the more massive components installed, the warp core takes a special place in the installation, for most shipyard crews consider this the heart of the starship. Contrary to perception, the computer core(s) are among the last of the major internal components installed. Man of the major systems, in fact, are manufactured and assembled at any one of a number of production facilities around the Federation. There are thousands of Starfleet contractors scattered around the Federation, and literally hundreds involved in the construction of any one starship. Many components may travel many light years to the construction site; some must go to other facilities for incorporation into other pre-assembled components. Most components and assemblies are small enough to transport via commercial shipper. Larger and more critical (and more sensitive or classified) hardware will travel by specialized Starfleet Transports.

As the framing nears the halfway point, crews begin the installation of some bulkheads and interior decking. As this continues, pressure bulkheads are installed in core areas, usually in and around the future atmospheric equipment bays. By design, it is important to complete these early, not only due to their centralized nature, but because they are among the first systems to be brought online during the continued construction. These areas will be sealed up, pressurized, and tested as other compartments adjacent to them are also enclosed. After passing all pressure tests, these compartments exist as habitable modules inside the ships open and exposed spaceframe. More compartments (that will eventually become the ships labs, workshops, quarters and equipment bays) are constructed, sealed, and pressure tested, all before being opened to the other already pressurized compartments. All during this time, crews are building the ducts, Jefferies Tubes, control / power conduits, ODN lines, SIF / IDF lines and hundreds of computer and communication circuits. Major internal systems, arriving at predetermined engineering schedules, are moved into position, secured to the spaceframe or decking fitted to existing connection lines and tested. The delivery timetables for each components delivery and installation are created by the engineers during the assembly planning. They are controlled by the Logistics Officer for the project, who has to deal with a marid of inevitable problems, magnified by the distances and complexities involved. After extensive testing and calibration, systems and sub-systems are brought online by using external power. As the habitable volume of the starship increases, several systems begin operating to self maintain this environment. Temporary airlocks are installed to allow worker access and it is not uncommon for workers to spend rest periods in these areas of the ship as opposed to the usually more crowded areas of the shipyard rest facilities. Simple portable amenities, such as replicators, cots, Holovids, and gaming tables are moved in to accommodate these workers. With more habitable volume available, technicians begin to install instruments and control consoles and several other major systems are installed. Such systems usually include the photon torpedo launcher(s), main sensors, navigational deflectors, phaser elements, transporter pattern buffers, and antimatter generators. Construction begins to increase as more and more specialized systems and specialized technicians arrive to handle them. Very quickly, limited TurboLifts are operating, a majority of the habitable volume of the starship is pressurized and self-maintaining, and many of the systems are online. Most systems still rely on shipyard power or portable fusion generators, and in fact the entire ship runs from a dedicated shipyard computer, programmed with customized software for this ship as it is handling the entire computer load of the yet unfinished starship. With the delivery of the computer core (or at least the first core if the ship has more than one) all the major internal components are in place.

As hook-ups are made and checked on all the different circuitry, crews are busy installing the non-pressure bulkheads, dividing the compartments into rooms that will become the working and living areas for the crew. Pressure bulkheads normally encompass several rooms and are designed to withstand several times the explosive force of a sudden decompression to maintain integrity from vented adjoining compartments. The non-pressure bulkheads can also withstand and sudden decompression, but lack the integrity to maintain pressure for longer periods. All bulkheads are installed with emergency force-field generators that allow breaches to be sealed, but these can be disrupted. As the non-pressure bulkheads are installed, secondary and auxiliary lines can be completed. This gives the ship and its systems tremendous redundancy in case of damage as system pathways have multiple routes to maintain their functional integrity.

END of Part I

Bibliography:

Star Trek The Next Generation Technical Manual by Rick Sternbach and Michael Okuda
Starfleet Dynamics by David Schmidt
Jackill’s Star Fleet Reference Manuals Vols 1, 2 and 3 by Eric Kristiansen
The Star Trek Encyclopedia by Michael Okuda and Denise Okuda
Star Trek The Next Generation Officer’s Manual by FASA Corporation