MERRILL A Keel Company

Powered by Merrill Technologies Group, the newly formed Keel Holdings sets out to supercharge the military’s nuclear-powered vessel supply network.

Faced with potential threats from China and Russia, the United States is under pressure to expand and modernize its submarine fleet. Keel Holdings, a new defense manufacturer, is stepping up to the challenge. The company combines the strengths of three top-tier, founder-led companies: Merrill Technologies Group, Metal Trades and Pegasus Steel. Each boasts a proven track record in supporting the nuclear Navy, including Columbia-and Virginia-class submarines and Ford Class Aircraft Carriers.

MERRILL is a titan in the world of large, complex metal fabrication. John Geiger is the president and COO of the Michigan manufacturer, long known for its expertise in design, engineering and machining. “We’ve invested more than $39 million in recent years to expand our capabilities,” says Geiger. “By aligning MERRILL’s offerings with the KEEL environment, we’re able to undertake even larger projects, better serve our customers and help defend the country.”

Bigger Reach, Greater Efficiency
Keel’s considerable resources include more than 13,000 square feet of best-in-class fabrication and machining facilities. In South Carolina, the company has direct deep-water barging access — a key advantage in the push to speed production and direct-to-customer delivery.

With its deep industry roots, Keel specializes in meeting stringent NAVSEA nuclear standards to support the safety and reliability requirements for surface and undersea naval platforms. From submarine superstructures to safety-critical navigation components, the company is positioned to deliver maximum benefit to defense customers.

“Individually, all three Keel companies have made significant contributions prior to the formation of Keel,” says Brian Carter, CEO of KEEL. “Under one umbrella, we’re now able to serve clients more efficiently by providing top-quality products from shipyards close to their locations.”

Merrill Technologies Group at the Core

While nuclear Navy projects are a key focal point for Keel, it is also committed to expanding across all programs, from heavy equipment to aerospace infrastructure. MERRILL plays a pivotal role in this integrated approach. Founded in 1968, the company brings design and engineering expertise to the table, along with its specialty in large-scale, fracture-critical steel fabrications.

Last year, MERRILL expanded its Michigan manufacturing floor space by 40,000 square feet, bringing its full capacity to 700,000 square feet. Recent upgrades include five-axis machining on some of the world’s largest equipment. “These technological advancements have long been a part of MERRILL’s DNA,” says Geiger. “Now, within the Keel platform, they are exposed to even larger parts and sections, such as those found in the Columbia-class submarine.”
Those five-axis machines on the MERRILL manufacturing floor include the Dinomax and the Raptocut — equipping the company to build structural components for defense, aluminum armored plates for ground vehicles and other large-scale projects. Also in MERRILL’s wheelhouse: electron beam welding technology, vital for building missile defense initiatives and components for space exploration.

There are also three new paint and blast booths— all with 90-foot dimensions that allow work on the largest structures. In MERRILL’s expanded wash bay, skilled workers handle chemical film washes and a multitude of spray coatings and topcoats. A new truck drive facilitates faster shipping access.

Engineering and Security Expertise at Merrill
Team MERRILL’s experienced engineers provide comprehensive solutions tailored to every project’s requirements. Whether optimizing designs for weight reduction or ensuring components will withstand extreme environments, they bring their knowledge and creativity to every challenge.
The MERRILL team develops complete mechanical, electrical and FEA engineering solutions with the use of 3D modeling software including CATIA, Solidworks, PTC Creo and Autodesk Product Design Suite.

The highly trained MERRILL team has been guarding performance specs, design and material implications of U.S. military products for more than 50 years. With secure facilities and continual vigilance, the company provides military-grade production security for the most sensitive projects.
Investing in the Future Workforce
As demand for defense manufacturing increases, so does the need for skilled workers. Recognizing the national shortage of trained welders, MERRILL founded the Merrill Institute in 2011. This innovative program provides on-site training in multiple types of welding, right in the company’s manufacturing facility. Students work on real projects and get an up-close look at what’s happening in the industry. The Merrill institute actively recruits veterans, supporting their transition to the civilian workforce and benefiting from their unique insights.

“With MERRILL at its core, Keel is ushering in the future of defense manufacturing with a skilled workforce, cutting-edge infrastructure and strategic partnerships,” says Geiger. “By focusing on innovation and investing in advanced equipment, we’re providing U.S. leadership in defense and technology for the future.”