Geoje shipyard
4.9 million m² site and
state-of-the-art
production system
Geoje shipyard
4.9 million m² site and
state-of-the-art
production system
Build a Ship
Each ship manufacturing process relies on the most efficient system with the
Just-in-time (JIT) method where a ship takes shape along the flow of resources
through the production process.
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1st Process
Design
We can design any type of ship that meets shipowner’s needs by ourselves. This independence in design technology served as the foundation for Korea to become No. 1 in the world’s shipbuilding industry.
In the initial design stage, based on the shipbuilding contracts and specifications, we design the hull and propellers and carry out model tests, do basic design, such as calculating the ship’s degree of listing and stability, and conduct structure design, such as the midship, main bulkhead, hull structure, deck, and external shapes.
In the detailed production design stage, we prepare a hull structure plan, a piping diagram, and plans for hull blocks and fittings.
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2nd Process
Steel Cutting
The process of cutting steel plates as designed.
The steel plates are coated with anti-rust paint and then sent into the cutting plant on a conveyor.
Here, based on the design information transmitted to the computer, a fully automatic cutting machine cuts steel plates according to the plan. Each cut steel plate is given a number and sorted by product type before being transferred for the assembly process.
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3rd Process
Assembly
The process of welding cut steel plates into large chunks (blocks).
The assembly plant has a flow production system. At the plant’s entrance, steel plates are attached. The vertical frame (longitudinal aggregate) and horizontal frame (transverse steel) are then fitted and welded along the conveyor line.
In our four large plants, 20 to 30 large blocks, each weighing 300 tons are produced daily.
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4th Process
Pre-outfitting
The process of pre-installing various ship fittings in the block assembly stage.
Various fittings, such as large pipes, cable trays and supporters, and machine foundations, are installed at the panel plant and the bow-and-stern plant. For the engine room, intricate equipment, pipes, and cables are installed in bundles at the pre-outfitting plant. This is to improve quality and productivity.
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5th Process
Painting
The process of applying paint on the steel ship to prevent rust.
The blocks manufactured at the assembly plant are sent to the painting plant via transporters, where their surfaces are polished with shot blasting before being applied with 3 to 6 layers of paint. For the block joints, the final finishing paint will be applied after the welding the block joints together in the dock.
We have four large painting plants that use eco-friendly paint. The paint is also highly corrosion-resistant, which increases the ship’s life significantly, and is harmless to the human body.
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6th Process
Erection
The process of stacking assembled and painted blocks on the dock to complete a ship.
Several small blocks are connected at the outdoor assembly site near the dock to form a large block. The large blocks are then stacked in the dry dock and welded to shape a complete ship.
In the case of 300,000-ton tankers, we assemble about 120 small blocks into around 80 large blocks, which are approximately 40m-long and 40m-wide and weigh about 780 tons, before lifting them up and stacking them using the 900-ton Goliath crane. This gives us competitive edge in the field of building large ships and offshore plants.
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7th Process
Launching
The process of floating the ship whose appearance is completed on the water.
After the ship’s body blocks, cabins, main engine, propellers, etc., are erected, it goes under the finishing painting work. Then, the dock is filled with water to float the ship.
Once the dock is completely filled with water, we open the floodgate (dock gate), pull the ship out with a tugboat, and move it to the quay wall for the finishing work. With thorough process management, we remove all the scaffolding from the dock and operate generators and boilers. The shipbuilding is already about 95% complete at the launching stage.
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8th Process
Outfitting
The process of installing all outfittings, such as various machinery, pipes, and electrical equipment, and finishing with a verification inspection.
The installation of various equipment, including the engine and boiler, cables, all facilities in the engine room, and electrical equipment on the pre-installed foundations, begins at the outdoor assembly site and in the dock. It is finished at the outfitting quay after the launching process.
90% of the outfitting work is done before the launch, when the working conditions are better, to ensure excellent outfitting quality.
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9th Process
Sea Trial
The process of testing all functions while operating the ship just like an actual voyage.
All machinery, including the main engine, generator, boiler, cargo unloading equipment, are powered on and tested at the quay wall before going out to the open sea to perform a sea trial under the same conditions as an actual voyage.
At this stage, we thoroughly inspect the ship to see whether everything works as defined in the contract and as designed without fail, while the shipowner and classification personnel witness the whole process.
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10th Process
Naming & Delivery
When the ship is finished, we hold a naming ceremony where the ship receives its name.
The naming of the ship is done by a woman nominated by the shipowner. Once the naming ceremony is done, the ship can finally be registered as a cargo ship.
With the delivery signature between the representatives of both companies, the ship’s ownership is transferred to the shipowner, which means the ship is ready to sail on. To ensure quality, we provide a one-year warranty service even after the ship is delivered.