Shipyard

A shipyard (also called a dockyard) is a place where ships are repaired and built. These can be yachts, military vessels, cruise liners or other cargo or passenger ships. Dockyards are sometimes more associated with maintenance and basing activities than shipyards, which are sometimes associated more with initial construction. The terms are routinely used interchangeably, in part because the evolution of dockyards and shipyards has often caused them to change or merge roles.

Countries with large shipbuilding industries include China, South Korea, Japan, the Philippines, Vietnam, Singapore, France, Russia, Germany, the Netherlands, Sweden, Ukraine, Finland, Denmark, Australia, India, Brazil, Taiwan, Romania, Poland . The shipbuilding industry tends to be more fragmented in Europe than in Asia. In European countries there are a greater number of small companies, compared to the fewer, larger companies in the shipbuilding countries of Asia.

Most shipbuilders in the United States are privately owned, the largest being Huntington Ingalls Industries, a multibillion-dollar defense contractor, and the oldest family owned shipyard being Colonna's Shipyard in Norfolk, VA. The publicly owned shipyards in the US are Naval facilities providing basing, support and repair.

Shipyards are constructed nearby the sea or tidal rivers to allow easy access for their ships. In the United Kingdom, for example, shipyards were established on the River Thames (King Henry VIII founded yards at Woolwich and Deptford in 1512 and 1513 respectively), River Mersey, River Tees, River Tyne, River Wear and River Clyde – the latter growing to be the World's pre-eminent shipbuilding centre.

Sir Alfred Yarrow established his yard by the Thames in London's Docklands in the late 19th century before moving it northwards to the banks of the Clyde at Scotstoun (1906–08). Other famous UK shipyards include the Harland and Wolff yard in Belfast, Northern Ireland, where Titanic was built, and the naval dockyard at Chatham, England on the Medway in north Kent.

The site of a large shipyard will contain many specialised cranes, dry docks, slipways, dust-free warehouses, painting facilities and extremely large areas for fabrication of the ships.

After a ship's useful life is over, it makes its final voyage to a shipbreaking yard, often on a beach in South Asia. Historically shipbreaking was carried on in drydock in developed countries, but high wages and environmental regulations have resulted in movement of the industry to developing regions.

Pollution

Having shipyards that have been operational for a long time could lead to serious pollution to the environment as years pass by. There have been many different studies that have shown that welding, sandblasting, paint, and maintenance are some of the many factors that contribute pollution to the environment. It is common for a ship to have a hull made of steel, but this process must go through many layers of anti-fouling or anti-corrosion paint to ensure that the metal doesn't corrode and prevent organisms from attaching to the surface. The painting process is inevitable but will it be at nearly every shipyard there is, and two of the most common ways to paint a ship is by airtight spraying and thermal spraying. Many studies have shown that painting is what generates almost half dangerous waste at a shipyard due to using high-pressure equipment to wash or remove any unwanted material that is on it like rust. Which will eventually make its way to the water and creates water pollution to the environment. Once these have compromised the surface of the hull the ship must go to the shipyard for maintenance. In a study in 2011 samples of sediments were collected from two sites in coastal marine area of Yongho Bay, one from the shipyard yard and the other 500m away.[1] These results had analyzed that both samples contained metals that included Al, Fe, Li, V, Cr, Mn, Ni, Cu, Zn, As, Cd, Sn, and Pb.[1] In addition, it had been confirmed that the concentration was higher in the first sample that was by the shipyard then the sample taking 500m away and was due to paint fragments applied to the steel ship hulls.

Solutions 

After a ship has been used it is then scrapped at a shipyard, but in the process can release excessive amounts of pollution. In paint used for hulls of the ship, they are anti-fouling based paint. Over time weathering from ships will eventually sink to the bottom of the seabed and the most common component that is toxic in paint used in shipyards is triphenyl (TPT) and can be treated by using dolomitic sorbents. In 2005, there was a study that show the high level of toxicity of TBT compounds to organisms in the ocean and what can be done to reduce the pollution by using dolomitic sorbents.[2] In the study, a sample of shipyard water was used in the experiment in a period over 14 days.[2] At the end the experiment it was concluded that dolomitic and dolomite were successful in reducing the contaminants from the shipyard wastewater.[2]

Welding

Welding is the most important factor in ship building and should be performed by qualified welders in order to protect the ship structure. It is achieved by heating the surfaces to the point of melting using oxy-acetylene, electric arc, or other means, and uniting them by pressing, hammering, etc. But in shipyards, there are times when the welder has to crawl into a confined space and weld. Welding can produce toxic fumes such as Nitric Oxide, Nitrogen Dioxide, Carbon Monoxide, Phosgene, Hydrogen Fluoride, Carbon Dioxide can also result in serious damage to human health or death if ventilation is not present. A case study was performed to see where would be most effective place to exhaust the hull cells on the bulkhead in between two spaces using an air horn versus air with an electric blower.[3] They used welders who were employees of the shipyard and asked them to weld in a specific space. One that had shipyard dilution ventilation(DV) and the other had local exhaust ventilation(LEV) then recorded to see which typed of ventilation worked the best.[3] In the results, they found that local exhaust ventilation reduced particulate concentrations but also the efficiency of either method depended on equipment maintenance and their own work practices because everyone has a different way of getting things done.[3]

History

The world's earliest known dockyards were built in the Harappan port city of Lothal circa 2600 BC in Gujarat, India. Lothal's dockyards connected to an ancient course of the Sabarmati river on the trade route between Harappan cities in Sindh and the peninsula of Saurashtra when the surrounding Kutch desert was a part of the Arabian Sea.

Lothal engineers accorded high priority to the creation of a dockyard and a warehouse to serve the purposes of naval trade. The dock was built on the eastern flank of the town, and is regarded by archaeologists as an engineering feat of the highest order. It was located away from the main current of the river to avoid silting, but provided access to ships in high tide as well.

The name of the ancient Greek city of Naupactus means "shipyard" (combination of the Greek words ναύς naus ship, boat and πήγνυμι pêgnumi, pegnymi builder, fixer). Naupactus' reputation in this field extends to the time of legend, where it is depicted as the place where the Heraclidae built a fleet to invade the Peloponnesus.

In the Spanish city of Barcelona, the Drassanes shipyards were active from at least the mid-13th century until the 18th century, although it at times served as a barracks for troops as well as an arsenal. During its time of operation it was continuously changed, rebuilt and modified, but two original towers and part of the original eight construction naves remain today. It is currently a maritime museum.

Ships were the first items to be manufactured in a factory, several hundred years before the Industrial Revolution, in the Venice Arsenal, Venice, Italy. The Arsenal apparently mass-produced nearly one ship every day using pre-manufactured parts, and assembly lines and, at its height, employed 16,000 people.

Historic shipyards

Ancient Shipyard of the Seljuks in Alanya, Turkey. The shipyard, consisting of five docks and constructed in 1226 by the Sultan Alaaddin Keykubat, is 56 metres long and 44 metres deep and is the only remaining shipyard from the Seljuks.

Prominent dockyards and shipyards

North America

Aerial view of Norfolk Naval Shipyard

South America

Brasfels Shipyard – Rio de Janeiro

Europe

Girvan shipyard Alexander Noble and son, Ayrshire Scotland

History, The Constanţa Shipyard was first mentioned as the Craft Repair Shop within the Constanţa Harbour area in 1892 by the Ministry for Public Works.[3] The first ship ever constructed by the shipyard and launched to sea on May 31, 1936 was a 12 metres (39 ft) long yacht named Crai Nou,[3] designed and built by Alexandru Theodoru a student at the Naval School in Constanţa and graduate of the French Naval School.[4] In 1950 the shipyard began to construct ships, pontoons, tugboats and towboats.[4] In 1975 the shipyard constructed one bulk carrier of 54,200 DWT which was the first large ship ever constructed in Romania.[4]

After the construction of a large bulk carrier Giuseppe Lembo in 1994, the shipyard reprofiled its activity to construct only small ships. Only after the privatisation in 2002 the shipyard restarted to construct large scale ships.[4] In the 114 years of existence the Constanţa Shipyard constructed 432 ships, 365 for Romanian shipping companies and 67 for shipping companies from Egypt, Russia, Greece, Japan, Hong Kong, Liechtenstein, Czech Republic, South Africa, Belgium, Germany, Italy, Norway, France, Panama and Netherlands, which have a total of 4,128,143 DWT.[4]

The shipyard is spread over an area of 980,000 square metres (10,500,000 sq ft), has three dry docks with a total length of 982 metres (3,222 ft) and 1.6 kilometres (0.99 mi) of berths.[4] In 2002 the company delivered two tankers of 42,500 DWT to the Norwegian company Kleven Floro used for the transportation of orange juice.[5] One of the main customers of the shipyard is the German company Hamburg Süd which ordered six container ships of around 6,000 TEU each, and seven ships of 7,100 TEU each as well as four tugboats.[6] The company also signed in 2005 an agreement with Mediterranean Shipping Company S.A., NSB Niederelbe, Gebab and Conti Reederei companies for the construction of 12 container ships of around 5,000 TEU each that will be delivered in stages until 2011 at a total cost of US$1.1 billion In 2008 the shipyard bought the largest gantry crane in North America, the Goliath Crane, formerly located in Quincy, Massachusetts from the General Dynamics company.[7] Built in 1975, the crane, nicknamed Goliath, Big Blue, The Dog or Horse, has a height of 100 metres (330 ft), a span of 126 metres (413 ft), a weight of 3,000 tonnes (6,600,000 lb) and a lifting capacity of 1,200 tonnes (2,600,000 lb).[8] The cranes's re-assembly has been under way since March 2009.

East Asia

South East Asia

Visakhapatnam Shipyard

South Asia and the Middle East

Cranes in Cochin Shipyard (India).
Dhaka Shipyard
Dhaka Shipyard – welding propellers

See also

References

  1. 1 2 Choi, J. Y., Hong, G. H., Ra, K., Kim, K., & Kim, K. (2014). "Magnetic characteristics of sediment grains concurrently contaminated with TBT and metals near a shipyard in Busan, Korea". Marine Pollution Bulletin. pp. 679–685. doi:10.1016/j.marpolbul.2014.03.029.
  2. 1 2 3  Walker, G., Hanna, J., & Allen, S. (2005). "Treatment of hazardous shipyard wastewater using dolomitic sorbents". Water Research. pp. 2422–2428. doi:10.1016/j.watres.2005.04.025.
  3. 1 2 3 Wurzelbacher, S. J., Hudock, S. D., Johnston, O. E., Blade, L. M., & Shulman, S. A. (2002). "A Pilot Study on the Effects of Two Ventilation Methods on Weld Fume Exposures in a Shipyard Confined Space Welding Task". Applied Occupational and Environmental Hygiene. pp. 735–740. doi:10.1080/10473220290096069.
  4. "Vigor Marine". Vigor Industrial. Retrieved July 6, 2012.
  5. "Company (about us)". TNG. Retrieved March 2, 2015.
  6. "SCRA". SCRA. Retrieved July 6, 2012.
  7. "TSK". Tsakos Industrias Navales S.A. Retrieved July 6, 2012.
  8. E-mail * Saisissez votre adresse électronique. "STX Europe démantelé, Fincantieri va devenir le géant européen de la navale" (in French). Mer et Marine. Retrieved 2013-04-30.
  9. "Submarine Museum marks Falklands 30th anniversary". BBC. May 2, 2012.
  10. "Yantai Raffles’ world-record gantry crane should see first lift this year – Offshore". Offshore-mag.com. Retrieved 2012-05-19.
  11. "Jurong Shipyard Pte Ltd". Jurong Shipyard Pte Ltd. Retrieved May 6, 2014.
  12. "Penguin Shipyard International".
  13. "Selat Melaka Shipbuilding Corporation". Selat Melaka. Retrieved July 6, 2012.
  14. "Surya Prima Bahtera Heavy Industries". SPB. Retrieved July 6, 2012.
  15. "The Bangkok Dock Company (1957) Limited". The Bangkok Dock Company. Retrieved July 6, 2012.
  16. "Marsun Company Limited". Marsun Company Limited. Retrieved July 6, 2012.
  17. "Marine Acme Thai Dockyard". MAT. Retrieved July 6, 2012.
  18. "Bason Shipyard's Brief History" (in Vietnamese). Bason Shipyard Website. Retrieved March 29, 2013.
  19. "PT Kim Seah Shipyard Indonesia".
  20. "PT Karyasindo Samudra Biru Shipyard Indonesia".
  21. "NorthStar Shipbuilding Pvt Ltd.". NorthStar Shipbuilding Pvt Ltd. Retrieved July 6, 2012.
  22. "Sulkha Shipyard". Sulkha Shipyard. Retrieved July 6, 2012.
  23. "Alang ship-breakers face Rs 2,000-cr hit from Rupee fall". The Economic Times. January 13, 2012.
  24. http://www.drydocks.gov.ae/en/portal/contact.us.aspx
  25. http://www.heisco.com
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