Ch11-H8070.

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11
Shipyard Layout
The past two or three decades have seen the emergence of a substantial
number of new shipyards, primarily in Asia and Eastern Europe, that
have been specifically planned to construct the larger ships being ordered
today, using contemporary shipbuilding practices and production methods.
A number of traditional shipbuilders have also established new yards
where they can also build larger ships and/or exploit the new technology
and production methods. In general the remaining shipbuilders will
have had to re-configure their site in order to utilise new technology
and improve production, whilst continuing to build ships. In many
cases the latter will still be restrained as to the size and type of ship
that can be built.
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 dock are located. The furthest area from the berths is
reserved for the material stockyard, and between the two are arranged in
sequence the consecutive work and shop processes. Too often existing shipyards follow the river bank, and are restricted by their location in a built up
area or the physical river bank slope from extending back from the river, so
that modified production flow lines are required.
Planning a new shipyard, or re-planning an existing one, will involve 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.
Shipyards usually have a fitting out basin or berth where the virtually
completed ship is tied up after launching and the finishing off work and
static trails may be carried out.

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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 11.1.
An idealized layout of a new shipyard is indicated in Figure 11.2 which
might be appropriate for a smaller yard specializing in one or two standard
type ships with a fairly high throughput so that one covered building dock
or berth was sufficient.
At this point it may be 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. They also give good crane

Plate
stowage

Section
stowage

Shotblast/prime

Shotblast/prime

Cutting
Marking
Shaping

Bending
cutting

Outfit materials
and bought in
items

Pipe bending

Outfit
fabrication
and assembly
Panel
Matrix
Subassemblies assemblies assemblies

Curved
unit
assemblies
Outfit
palletisation
and
modules

Block
assembly
Block and unit
erection

Final outfit

FIGURE 11.1 Shipbuilding process

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113

Plate and section stockyard

Admin
offices

Marshalling and preparation

Plate
and
section machining

Module
assembly
Unit
assembly areas

and pallet
preparation
Pipe and
engine shop

Block fabrication

Covered
building
dock

Outfit
shops
Fitting out
basin

FIGURE 11.2 Shipyard layout

clearance for positioning units. The greatest disadvantage of the building

dock is its high initial cost.
Many yard re-constructions have incorporated undercover construction
facilities in the form of docks or slipways within building halls. Others
have building halls at the head of the slipway with advanced transfer systems installed so that the hull can be extruded out of the hall onto the
slipway for launching. Such facilities permit ship construction in a factory
type environment providing protection from the worst effects of weather
and darkness.

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Ship Construction

Further Reading
Brandnew Portsmouth complex for VT, The Naval Architect, July/August,
2003.
Chinese shipbuilders on the way to the top, The Naval Architect, September
2005.
Covered hall benefit for Bijlsma, The Naval Architect, May 2002.

Some Useful Web Sites

Shipyards
www.marine.alstom.com
www.shi.samsung.co.kr

see Building a ship construction phases

take the virtual tour of the Geoje Shipyard