UNIT 3: SHIP CONSTRUCTION 1

UNIT 3: SHIP CONSTRUCTION

Lesson 4: Shipyard Layout

Part A: Reading Comprehension
D. J. Iyres. 5th Ed. (2001). Ship Construction Butterworth-Heinemann, p. 105.

Most shipyards are well established and were originally sited in a suitable
location for building small ships. With the growth in ship sizes and the
introduction of new building methods it has been recognized that a modified
shipyard layout will be advantageous.

Advantages to be gained, apart from the ability to construct larger vessels, are a
uniform work load, a shorter ship build cycle, and economies in construction
practices. These are obtained by having a layout that lends itself to an easy flow
of materials from one productive process to another with elimination of
bottlenecks. Other factors off course are involved in achieving a smooth
production flow, but it is an advantage to start with a shop and equipment layout
which is favorable.

Very rarely has it been possible for shipbuilders to select a new site and adopt an
ideal layout. Normally the present site has to be used, and it is necessary to make
modifications to make the site ready for new purposes. At the same time
shipbuilding has continued within the yard, and overall yard modifications have
been made gradually in order not to delay this work seriously.

An ideal layout for a modern shipyard is based on a production flow basis, with
the yard extending back from the river or shore at which the berths or building
docks are located. The furthest area from the berths is reserved for the material
stockyard. Between the berths and material stockyard, the consecutive work and
shop processes are arranged in sequence. Too often existing shipyards follow the
UNIT 3: SHIP CONSTRUCTION 2

river bank, and are restricted by their location in a built up area or the physical
river bank slope, so that modified production flow lines are required.

Planning a new shipyard, or re-planning an existing one, will include decisions

to be made on the following:

 Size and type of ship to be built

 Material production per year to be achieved
 Material handling equipment to be supplied
 Machining processes to be installed
 Unit size and weight to be fabricated and erected
 Amount of outfit and engine installation to be undertaken
 Control services to be supplied
 Administration facilities required

Before considering the actual layout of the shipyard it is as well to consider the
relationship of the work processes involved in building a ship as illustrated in
Figure 4.1.

Shipyards usually have a fitting out basin or berth where the virtually completed
ship is tied up after launching and the finishing off works are completed. Fitting
out basin or berth is provided with adequate craneage and the outfitting and
machinery shops are usually adjacent to it. Nowadays the major part of the outfit
and machinery are installed in modular form during the hull fabrication cycle.
Therefore, this feature of the yard now has less significance.

An idealized layout of a new shipyard is indicated in Figure 4.2 which might be

appropriate for a smaller yard specializing in one or two standard type ships so
that one covered building dock or berth are sufficient.

At this point it is convenient to mention the advantages and disadvantages of

building docks as opposed to building berths. Building docks can be of
advantage in the building of large vessels where launching costs are high, and
there is a possibility of structural damage owing to the large stresses imposed by
a conventional launch. Dry docks also give good crane clearance for positioning
units. The greatest disadvantage of the building dock is its high initial cost.
UNIT 3: SHIP CONSTRUCTION 3

Figure 4.1. Shipbuilding process

UNIT 3: SHIP CONSTRUCTION 4

Figure 4.2. Shipyard layout

UNIT 3: SHIP CONSTRUCTION 5

Part B: SNAPSHOT – DAMEN Shipyard, Mangalia, Romania

UNIT 3: SHIP CONSTRUCTION 6

Part C: Home Work – Team Work

Investigate about one of the largest shipyards in the specified country for
each group of students as defined in below table.
Student No. Country
1-3 China
4-6 S. Korea
7-9 Japan
10 - 12 Germany
13 - 15 Italy
16 – 18 UK
19 - 21 USA
22 - 24 UAE
25 – 27 Turkey
28 - 30 Azerbaijan
Specified countries can be changed subject to prior notice and approval.
The investigation must include (at least):
 History of the shipyard
 Type of ships constructed in the shipyard
 Yard equipment and construction facilities
 Yard layout (from google map) specifying different shops and construction
areas