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12 ERECTION OF BULK UNITS

12.1 AIMS OF THE LECTURE

a) To outline the procedures of lifting the blocks,units and modules to the building berth or
dock.

b) To explore the erection scheduling methods.

c) To examine the hazards in lifting bulk structure


12.2 LIFTING PROCEDURES

Lifting procedure is a method of lifting the ships bulk structure such as blocks, units, and
modules to the building berth or dock. The procedure should be well considered because it
involves large and heavy structures, which conceives many hazards both to the production
process as well as to the human safety.

The lifting procedure considerations would include the followings:

a) Lifting facilities

The lifting facilities available for lifting the blocks onto the berth or dock should be identified
far before the blocks are ready to be lifted. It was when the size and weight of the blocks
were determined prior to their construction in the assembly shop.
Cranes that are commonly used for lifting the blocks are gantry crane which is also known as
Goliath crane, telescopic mobile crane, hammerhead crane, floating crane, and level luffing
crane.








Figure 12.1 Goliath crane

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Figure 12.2 Telescopic mobile crane
Figure 12.3 Hammerhead crane
Figure 12.4 Floating crane

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The decision of using the type and capacity of certain crane is based on investment cost and
utilisation of the crane, the type and size of ships will be built, the efficiency and practicality
of using it etc., some considerations of choosing the type of crane are shown in the following
matrix of merits and drawbacks:
No Type of crane Merits Drawbacks
1 Goliath crane - High lifting capacity
- Can cover the whole area of
dock or berth
- Very stable
- Good operator visibility
- High invesment cost
- Not applicable on side
launch berth
2 Telescopic mobile
crane
- Can move around easily
- Suitable for lifting small
units
- Lower investment cost
- Can be hired
- Limited in lifting capacity
- Not very stable
- Limited operator visibility
- Limited coverage
3 Hammerhead crane - High lifting capacity
- Very stable
- Good operator visibility
- Good coverage
- Applicable for side launch

- High invesment cost
- Operate only from one side

4 Floating crane - High lifting capacity
- Can be operate from water
front
- Good for complementary
task

- Limited coverage
- Limited stability
- High invesment cost
- Not applicable on end
launch
- Limited operator visibility
-
5 Level luffing crane - High lifting capacity
- Can work in tandem
- Applicable in all type of
launch
- Limited stability
- Limited coverage

Figure 12.5 Level luffing crane

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b) Size and weight of blocks
In most modern shipyards that implement advanced outfitting method blocks and modules are
completed in the assembly shop or on the assembly yard, in order to minimise the joining
process on the berth or dock. It is a common practice to construct the blocks as large as
possible as the lifting facilities allow.
There are some advantages in having large and complete blocks to be erected to the berth or
dock, but the drawbacks should also be considered.

Advantages and disadvantages of large block structure
Advantages Disadvantages
Minimum work on berth/dock Need high capacity of cranage
Shorter construction time on berth/dock Demand high accuracy of block structure
Better product quality More difficult to align the blocks
Less disruption to complete the block Need higher skill to lift the blocks

Some considerations that should be made in deciding the size and weight of the blocks with
regard to the efficientcy, practicallities, and cost effectiveness of the shipyard are as follows:
The capacity of the transporter available to transfer the blocks to the berth or dock.
The lifting capacity of cranes available on the berth or dock.
The access available for transporting the blocks to the berth or dock.
The alignment methods that will be implemented on berth or dock.
The lifting methods that will be implemented.






















Figure 12.6 Block transporting

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c) Arrangement of lifting points

The shape of modules or blocks to be erected to the berth or dock are not always symmitrical,
therefore in order to obtain a good balance in lifting the blocks, the positioning of lifting
points needs to be considered well.

Some considerations in arranging the lifting points are as follows:

The shape of the structure to be lifted
The position of its center of gravity
The position of strong and weak structural members
The framing system of the structure
The lifting method to be applied





































Figure 12.7 Block lifting
Figure 12.8 Lifting points

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d) Preparation of reference lines and points

For proper alignment of the blocks on building berth or dock reference lines are drawn on the
floor and walls (for dock) with some indication of their positions relative to the centerline for
floor reference lines, and relative height and distances from the floor for horizontal and
vertical reference lines as shown in the following illustration:








Reference lines and reference points are not only drawn on the floor and walls of the berth or
dock, but also drawn on the blocks and on some of their structural members.
Prior to joining the block is positioned on the prepared stools or on top of other blocks, the
reference lines and reference points are used as guidance for its correct position.
e) block alignment
Unlike building a boat or conventional method where the ship was constructed piece by
piece, most of the ships now are built in blocks and modules. The blocks and modules are
aligned on their designated positions prior being tack welded and joined one to another.
Block alignment is important for obtaining a good shape of the ships hull, and for proper
joining of the internal structural and outfiting parts.
In block aligning reference lines and points both on the berth and on other blocks are used as
guidnace for its position, and a number of tools are also being used such as theodolite and
laser beam.











Vertical reference line
Horizontal reference line
CL
Floor reference line
Figure 12.9 Docks reference lines
Figure 12.10 Theodolite

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12.3 ERECTION SCHEDULE
The completion of blocks joining dependent on the launching method that will be
implemented. If the ship is launched on the slipway for safety reasons, most of the super
structure usually will be completed on the quay after the launching, but if the ship is floated
out the whole structure would be completed on the berth or dock.
The effectiveness of blocks joining process among other things will be determined by the
block erection schedule. Many aspects should be considered in order to obtain an optimum
block erection schedule these include:
The position of blocks in the ship structure
The blocks joining sequences
The work content and the time needed to construct each block in the shop
The work content and the time needed to join each block
Traditionally block erection schedule was done manually using past project or experienced
data, which generally very time consuming and very unaccurate. Some computer
programmes have been introduced to do the scheduling task using numerical algorithm and
visual simulation.
Information for block erection schedule would come in many ways include:
Network diagram
Blocks layout sketches
Block erection matrix

Figure 12.11 Block alignment























Block
Number
Preceding
Block
DB 3 PS DB 4 SB
DB 3 SB DB 3 PS
DB 2 PS DB 3 SB
DB 2 SB DB 2 PS
DB 1 PS DB 2 SB
DB 1 SB DB 1 PS
Figure 12.14
Preceding
Block
Successing
Blocks
Erection Due Joining time
(days)
DB 4 SB DB 3 SB 3 Jan 09
DB 3 PS DB 2 PS 6Jan 09
DB 3 SB DB 2 SB 9 Jan 09
DB 2 PS DB 1 PS 12 Jan 09
DB 2 SB DB 1 SB 15 Jan 09
DB 1 PS FP 1 19 Jan 09
Figure 12.12 Block structural breakdown
Figure 12.13 Network diagram
14 Example of blocks erection schedule matrix
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Joining time
(days)
3
3
3
3
4
4

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12.4 LIFTING HAZARDS
There are some hazards that need to be anticipated in lifting a bulk structure such as block,
module, and unit, because of the potential risks that might create fatal consequences both to
the human safety as well as to the work being carried out.
a) Identified hazards
The lifting hazards that may be identified among other things are:
Unsymmetrical shape of the module, unit, or block being lifted that might cause
unballance lifting and the structure fall down.
Size and weight of the structure being lifted that make the lifting process more dificult
to control.
Cranes working in tandem might cause unsynchronised movement and lifting speed
and break the ropes or lifting points.
Improper securing of lifting points which might caused the lifting points pulled off the
structure.
Inaccurate positioning of the structure which can cause mismatch of the joining parts.
Unqualified operator being emplyed may violate the lifting procedures

b) Potential risks
The potential risks due to lifting hazards can be categorised into two groups as follows:
Production risks Safety risks
Rework Injury to the people
Damage of the structure Inconvenient working condition
Lengthen the production time Work disruption
Extra working cost
Work does not meet the standards

c) Risks reduction
Actions that could be made to reduce the risks due to lifting hazards are:
Implement proper lifting procedures
Employ qualified lifting operators
Examine the structure and the facilities before undertaking the task
Arrange the lifting points properly by considering the shape and weight of the
structure

12.6 CONCLUDING REMARKS
a) Lifting procedure is a method of lifting the ships bulk structure to the building berth or
dock.

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b) The lifting procedure considerations would include:
Lifting facilities
Size and weight of blocks
Arrangement of lifting points
Preparation of fererence lines and ponits
Blocks alignment

c) Considerations on erection schedule should include:
The position of blocks in the ship structure
The blocks joining sequences
The work content and the time needed to construct each block in the shop
The work content and the time needed to join each block

d) Hazards that need to be identified in lifting bulk structure include:
Unsymmetrical shape of the structure
Size and weight of the structure
Cranes working in tandem
Improper securing of lifting points
Inaccurate positioning of the structure
Unqualified operator being employed

e) Potential risks in lifting bulk structure can be grouped into production risks and safety
risks.

f) Some consideration for reducing risks include:
Implement proper lifting procedures
Employ qualified lifting operators
Examine the structure and the facilities before undertaking the task
Arrange the lifting points properly by considering the shape and weight of the
structure