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Work we can talk about.

Every project delivered by Charlie Frey is documented in detail — challenge, solution, measurable outcome. These are the engagements our clients have given us permission to share publicly.

Projects Shown 08

Years Covered 2025 — 2026

Total Fleet Hours Saved > 2,400

Lost Time Incidents ZERO

CF-26-88412026 / MAR · ROTTERDAM

M/V Atlas Horizon — Emergency Propeller Recovery

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Propeller PolishingEmergencyCLASS S

Challenge

Container vessel suffered fishing-gear entanglement en route to Rotterdam. Classification society required immediate verification of propeller integrity before the vessel could sail to its next port.

Solution

Two dive teams mobilized within four hours. Removed debris, performed Rugotest baseline, polished to ISO 484 Class S, and captured full photographic evidence. Class surveyor witnessed final inspection at anchor.

Outcome

Vessel departed on schedule. Zero off-hire time. Fuel efficiency restored to 98.4% of design baseline. Full dossier archived in Fleet.io within 24 hours of completion.

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CF-26-87762026 / FEB · FUJAIRAH

VLCC Pacific Crane — Thruster Seal Replacement

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Thruster RepairVLCCIN-SITU

Challenge

Main tunnel thruster seal failure on a laden VLCC. OEM recommended dry-docking, which would have cost an estimated $2.1M in deferred revenue and diverted the vessel 6,400nm.

Solution

Engineered in-situ seal replacement procedure using habitat box and custom inflatable plugs. Dive team executed the work over 38 hours across three shifts at anchor.

Outcome

Seal replaced to OEM specification. Thruster returned to full service. Vessel continued its laden voyage without deviation. Saved client approximately $2.1M in deferred revenue and fuel.

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CF-26-86022026 / JAN · HOUSTON

Port of Houston — Pier 32 Pile Rehabilitation

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Marine ConstructionPort Infrastructure42 PILES

Challenge

Forty-two reinforced concrete piles at Pier 32 showed critical spalling and exposed rebar after four decades of tidal exposure. Port authority required repair without taking the pier out of service.

Solution

Deployed our proprietary subsea form system, which allows concrete pours in-situ without cofferdams. Executed pours during low-traffic windows over eleven weeks.

Outcome

All 42 piles restored to full structural capacity. Pier remained operational throughout. Project delivered three weeks ahead of schedule with zero lost-time incidents.

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CF-25-85112025 / NOV · SINGAPORE

LNG Carrier Polaris Mist — Insert Weld Repair

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Underwater WeldingLNGCLASS A

Challenge

LNG carrier sustained impact damage to hull plating in the aft cofferdam region. Class society required a Class A repair equivalent to surface welding before the next loading.

Solution

Hyperbaric dry-habitat built over the damaged area. Certified AWS D3.6M Class A welder executed insert plate repair. Full NDT including UT and MPI verification after welding.

Outcome

Class A certification issued by Lloyd's Register within 48 hours. Vessel loaded on schedule. No repeat inspection required at next class renewal.

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CF-25-79082025 / SEP · PANAMA

Fleet-Wide Hull Clean — 14 Product Tankers

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Hull CleaningFleet Program14 VESSELS

Challenge

Regional tanker operator facing rising bunker costs and pending CII rating downgrade. Needed rapid, fleet-wide hull cleaning without disrupting charter commitments.

Solution

Scheduled in-water hull cleanings around each vessel's Panama Canal transit window. Deployed two dive teams in parallel. Used closed-loop effluent capture to comply with local regulations.

Outcome

All 14 vessels cleaned in 19 days. Average 6.8% fuel efficiency recovery across the fleet. Operator avoided CII downgrade and reported $4.3M in annual fuel savings.

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CF-25-76222025 / JUL · LOS ANGELES

Cruise Line Oceana Queen — Stabilizer Fin Repair

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Drive SystemsCruise2-DAY TURN

Challenge

Luxury cruise vessel sustained starboard stabilizer fin damage during docking. Charter sold out for next sailing — no time for dry-dock.

Solution

Mobilized precision fin repair team overnight. Removed damaged fin, installed replacement, and restored stabilizer system to full operation during 36-hour turnaround in port.

Outcome

Vessel sailed on schedule with full stabilizer functionality. Guest experience uninterrupted. Operator retained all charter revenue.

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CF-25-73442025 / APR · PIRAEUS

M/V Hellenic Spirit — Rope Cutter Retrofit

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Thruster RepairRetrofitROPE CUTTER

Challenge

Short-sea operator suffering repeated propeller entanglements in Greek waters. Required rope cutter installation on all four vessels in the fleet without dry-docking.

Solution

Designed a custom mounting bracket compatible with the existing shaft configuration. Retrofitted all four vessels during scheduled port calls over six weeks.

Outcome

Entanglement incidents reduced to zero in the first operating year. Combined fuel savings from fewer emergency propeller repairs exceeded the retrofit cost in seven months.

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CF-25-68902025 / FEB · GIBRALTAR

Harbor Tug Iberia — Full Class Renewal Survey

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Class SurveyIWSTUG

Challenge

Tug operator required in-water class survey to extend dry-docking interval. Needed full hull, propeller, and anode inspection with class witness.

Solution

Executed complete IWS to ABS requirements: UT thickness gauging, anode wastage measurement, propeller inspection, and high-definition photographic documentation.

Outcome

Class renewal granted in full. Dry-docking deferred by 30 months — representing approximately $380K in avoided costs for the operator.

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