Facilities

Dock 1 and the 900-ton Goliath crane

Entered in the Guinness Book of World Records for the World's Largest

The only dock in the world with a capacity of building up to 1 million DWT oil carriers and plants with a length of 120 m and a height of 130 m Dock 1 which is the largest in the world recorded in the Guinness Book of World Records, is equipped with a 900-ton Goliath crane and has the capacity of building an oil carrier up to 1 million DWT (515 m in length) and a plant that measures 120 m in width and 130 m in height.   Dock 1 also has six 50~200 ton Jib cranes to support the work at the outdoor assembly yard and within the dock.

Dock 2 and the 900-ton Goliath crane

Capacity of building a 1 million DWT vessel and a plant with a width of 80m

A 900t Gantry crane and three Tower cranes are in operation In Dock 2, which is specialized in building ultra-large container ships, car carriers, and oil carriers, has a capacity of building up to 1 million DWT vessels and plant with a width of 80 m. A 900t Gantry crane and three Tower cranes are in operation.

Training Center

Training Center for Highly Skilled Workforce

Founded in 1973 and received a Gold Tower medal from the Korean government in recognition of its outstanding accomplishments in training. This is a training center to grow highly skilled talent who are the prerequisites for high-quality products. All the employees of us receive one to three regular training classes a year to maintain and improve their skills, and the employees of affiliates receive skill improvement training and acquire necessary certifications here. Since the center's founding in 1979, it has trained tens of thousands of skilled labor and received a Gold Tower medal from the government in recognition of its outstanding contribution.

Industrial Technology Research Center

Research and development for all the technologies required for building, installation, and operation of ships and offshore plants

Research on design technology/welding technology/performance analysis/simulation and other necessary technology for the business It is the place where research and development take place for foundational and element technologies related to building, installation, and operation of ships and offshore plants. The center covers a wide range of research areas including welding technology, layouts for process and equipment automation, navigation performance analysis, simulation, high-performance and high quality coating materials and mechanical properties evaluation technology, environmental friendliness, and energy conservation.

Pre-outfitting Shop 1

Manufacturing and installation of various outfitting items such as pipes, wires, electrical equipment, and mechanical devices

We maintain high productivity using the pre-outfitting method This is the place where various outfitting items including pipes, wires, electrical equipment and mechanical devices are manufactured and installed. Our use of the "pre-outfitting method" resulted in increased productivity as 80% of the outfitting items are fitted on blocks in advance at the outfitting ship.

Small Part Assembly Shop

Semi-automatic welding carriages are used to minimize heat distortion and ensure high quality welding

A place where the steel plates cut from the cutting shop are welded for the first time This is a shop where all the small steel pieces cut from the cutting shop are melted and welded for the first time. The joined steel plates will be attached to the main frames of the ship in the following assembly processes. In this shop, semi-automatic welding carriages are used to minimize heat distortion and ensure high quality welding.

Ocean Plaza

Design teams consolidated, and the buildings completed in April, 2011

Equipped with a state-of-the-art intelligent building system that features cutting edge equipment and a high-speed communications network With a recent consolidation of the design divisions, We completed the Ocean Plaza in April, 2011 to house all design related departments. This is the powerhouse of our technology where designing of commercial ship, offshore plant, and specialty vessel and material procurement are carried out. The place is where a dynamic group of design engineers, researchers, and procurement specialists works with a state-of-the-art intelligent building system that includes the latest equipment and a high-speed communications network.

Waste Water Treatment Plant

Treats wastewater from the shipyard through a biological treatment process that uses micro-organisms

Purified wastewater from 160 places, recycled for the production process All domestic wastewater collected from the shipyard is treated in this facility through a biological treatment method that uses micro-organisms. Domestic wastewater from over 160 places such as bathrooms, restaurants, and showers are transferred from reservoirs and the pump stations to the waste treatment facility through a pipeline which extends about 26 km long. The wastewater is treated within 30% of the legal BOD limit (under 6 ppm) and recycled for the production process.

Outfitting Quay

Quay wall equipped with four 30~50 ton jib cranes and one 60 ton traveling tower crane

A place used for outfitting installation and trial runs of the ships or plants while keeping them afloat We have a 3,600 m long quay wall that is used to float ships and plants during fitting out and trial runs. The quay wall, which is 11 to 14 m deep under the water, is equipped with four jib cranes in the range of 30 to 50 tons and one 60-ton traveling tower crane.

Pretreatment and Painting Shops

The premium painting that holds up over 20 years of navigation

A process of applying 3-4 coats of paint after the surfaces are blasted to remove the contaminants This is a shop where the surfaces of the completed blocks are blasted to remove contaminates and 4 to 6 coats of paint is applied. Each painting shop is equipped with a large dust collecting system and humidity control system to provide the optimal painting conditions and improve air quality. Our painting technology boasts durability that holds up over 20 years of navigation.

Cutting Shop

Equipped with fully automated plasma cutting system and gas cutters

Automatically cuts and produce clean-cut edges according to the designs In this process, the steel plate surfaces that were processed, pretreated and painted are cut according to the design information. The shop is equipped with various fully automated plasma cutting equipment and gas cutters including the automatic marking system.   Cutting of flat steel plates as well as section steel such as T-bars and processing of the cut edges are all automated.

Assembly Shop 1 and 3

Hull blocks manufactured for the midship, the body of a ship, using

large-scale automated systems such as an automated plate joiner and an automated longitudinal joining and welding device "Assembly Shop 1" and "Assembly Shop 3" are where the midship, the body of a ship, is made. They manufacture blocks which comprise the hull of a ship with large automated equipment such as an "automated plate joiner" that is used to join large steel plates and an "automated longitudinal joining and welding device" that is used to adhere the frame on the long side of the ship.   These are two of the largest shops at Shipyard which are famous for making the strongest hulls using its unique the "dual-slit method" that the slit in a transverse frame of a ship is joined with the slit in a longitudinal steel frame.   In addition, they have dozens of cutting edge equipment including automated welding robots and submerged welding machines.

Assembly Shop 2

A shop where a 3D curved hull is formed

3D precision measuring system used to precisely measure the sizes of compound blocks within ±2mm deviation This is a shop where the plates are formed for the ship hull with compound curves using a large press and line heating process technology. The shop is equipped with an overhead travelling crane and a large press for flat and curved plates, and is capable of measuring a block as big as 10 m with great precision, within ±2mm deviation, using the 3D precision measuring system based on a laser range finder and a computer. It also has cutting edge equipment such as automated pin jig that provides automatic support for curved bottom blocks to craft attractive curves of the bow and stern.

Floating Dock

Three docks in the Okpo Shipyard Used for building, re-launching, or repairing specialty vessels and mid-to-large ships

We have Three 150,000-ton floating docks. The Floating Dock 1, which can accommodate Suezmax ships, has the capacity of re-launching and repairs of 78,000 CBM LNG carriers. Floating docks are used to efficiently build, re-launch, and repair specialty ships such as destroyers and mid-to-large size ships.

Loading Quay and Steel Yard

Used to unload and store the steel plates transported by sea

Stores the steel plates by the size, and moves them on a conveyor system to the cutting shop This is the place where steel plates that are transported by ship are unloaded and stored. A large unloading crane is in operation in the loading quay, and the steel plates are organized by their sizes in the steel yard that covers an area of 45,000 ㎡ and moved on a conveyor belt system to the cutting shop.

Offshore Plant Outfitting Shop

A place where outfitting items are pre-fitted

Pre-fits the outfitting items before assembling of large blocks to increase quality and productivity This is where the outfitting items such as plumbing, steel outfitting items, ventilation equipment, electrical/wiring, and machinery are pre-fitted after the hull blocks for the offshore plants are made. In the production of an offshore plant, We divide various outfitting items into separate sections at the block stage and pre-fits them before the large blocks are assembled, thereby increases quality and productivity.

Offshore Plant Manufacturing Shop 1

Manufactures hull structures for offshore plants

A multi-purpose shop that assembles small and medium-sized blocks and manufactures casting structures and special shaped structures such as curved bottom plates and cylinders This is where various the main structures of an offshore plant are made. In this shop that comprises 4 bays, the steel plates which were cut according to design specs are joined with the section steel, and small blocks are joined to make larger blocks. This is an all-purpose shop that manufactures casting structures and special structures such as curved bottom blocks and cylinders. The shop uses a flow production line system equipped with the latest automated equipment including two 100t and 50t cranes each, sub-assembly conveyor line, and automated welding equipment to ensure high productivity and quality.

Offshore Plant Manufacturing Shop 2

A medium assembly shop for offshore plants

A medium assembly shop for flat bottomed blocks where longitudinal plates are attached to the large steel plate and the exterior hull plate. This is where the flat bottomed blocks are assembled. The longitudinal frames are attached to the exterior plate of the hull and to the large main frame steel plate,   It is equipped with a crane and automated welding equipment that can weld 16 longitudinal plates at the same time, and feeds deck longitudinal plates and medium-sized flat bottomed blocks to the large block assembly process in the offshore plant manufacturing shop 1 and 3. 

Offshore Plant Manufacturing Shop 3

Large block assembly for offshore plants

A large assembly shop for assembling and joining large blocks This is where large blocks are joined to make larger blocks for offshore plants. It is the largest single shop among the shops at Shipyard with a site covering 210 m in length, and 54 m in width. The shop is equipped with 250t and 50t overhead travelling cranes and a pin jig surface plate for large assembly, and capable of manufacturing blocks of all shapes.

Offshore Plant Pretreatment and Painting Shops

Climate-controlled painting and pretreatment shops featuring the latest equipment

Pretreatment and final painting of the surfaces of blocks before erection to the plant This is where the surfaces of large super blocks are treated and painted with the final coat before being erected. The shop is equipped with the latest automated humidity control system. In the pretreatment shop, the surfaces of steel plates are abrasively blasted to make the paint stick better. The painting shop where the pretreated blocks are painted is humidity and temperature controlled providing optimal conditions for high quality painting regardless of outside weather conditions. These two shops are located side by side, which enables successive operations from pretreatment to painting of a large block as big as 40 m in width and in length.

Offshore Plant Pretreatment and Painting Shops

Climate-controlled painting and pretreatment shops featuring the latest equipment

Pretreatment and final painting of the surfaces of blocks before erection to the plant This is where the surfaces of large super blocks are treated and painted with the final coat before being erected. The shop is equipped with the latest automated humidity control system. In the pretreatment shop, the surfaces of steel plates are abrasively blasted to make the paint stick better. The painting shop where the pretreated blocks are painted is humidity and temperature controlled providing optimal conditions for high quality painting regardless of outside weather conditions. These two shops are located side by side, which enables successive operations from pretreatment to painting of a large block as big as 40 m in width and in length.

LNG Carrier Insulation Box Manufacturing Shop

A capacity of building cargo tanks for eight140,000-cu m LNG carriers annually

Automated facility for manufacturing 50,000 insulation boxes monthly and for processing enough INVAR steel for eight vessels annually We have manufacturing facilities capable of building cargo tanks for eight 140,000-cu m LNG carriers a year. These automated facilities have the capacity of manufacturing as many as 50,000 insulation boxes monthly and processing enough INVAR steel for 8 vessels annually. Receiving classification certificates for those processing equipment, which were developed 100% in-house, completed our list of certificates required in building LNG carriers. The insulation box manufacturing shop in the Anjung Industrial Complex in Tongyeoung, Geongnam, has been manufacturing about 350,000 insulation boxes to be used for nine vessels a year since July 2002

Assembly Shop 1 and 3

Hull blocks manufactured for the midship, the body of a ship, using

large-scale automated systems such as an automated plate joiner and an automated longitudinal joining and welding device "Assembly Shop 1" and "Assembly Shop 3" are where the midship, the body of a ship, is made. They manufacture blocks which comprise the hull of a ship with large automated equipment such as an "automated plate joiner" that is used to join large steel plates and an "automated longitudinal joining and welding device" that is used to adhere the frame on the long side of the ship.   These are two of the largest shops at which are famous for making the strongest hulls using its unique the "dual-slit method" that the slit in a transverse frame of a ship is joined with the slit in a longitudinal steel frame.   In addition, they have dozens of cutting edge equipment including automated welding robots and submerged welding machines.

Build a ship

The 1st Process

Design

Our technology allows us to design any type of vessels requested by ship-owners, which laid a solid foundation for this country to be the top in the world's shipbuilding industry. In the initial stage, the hull form and propellers are designed based on the building contract and specifications, and simulation tests are performed. Then, the structural designs are developed for the midship, major bulkheads, hull structure and decks, and the exterior of the shop, together with the basic design. In the detailed production design stage, the plans for the hull structure, plumbing, blocks, and outfitting items are created.

The 2nd Process

Steel Cutting

This is the process of cutting steel plates according to the designs. The steel plates are coated with anti-corrosive paint and moved to the cutting shop on the conveyor. Based on the design information sent to a computer, the steel plates are cut into shapes by the fully automatic cutting machines. The steel plate cut-outs with individually assigned ID numbers are moved to applicable assembly processes for each product.

The 3rd Process

Assembly

This is a process of welding the steel cut-outs into a big block. The assembly shop has a continuous flow system that the flat and curved bottomed plates are welded at the beginning of the process, the transverse frames are joined with the longitudinal frames, and then welded on a conveyor line to take the final shape. We produce 30 to 40 300-ton blocks daily in its 5 large-scale shops.

The 4th Process

Pre-Outfitting

This is a process where various outfitting items of a vessel are pre-fitted during the block assembly stage. Various outfitting items including large pipes or electric wire brackets, and machine mounts are fitted in the panel shop and bow & stern shop. The equipment, pipes and wires for a complex engine room are installed in bulk in the pre-outfitting shop to increase the quality and productivity.

The 5th Process

Painting

This is the painting process to prevent corrosion on metal ships. The blocks manufactured in the assembly shop are transferred on a transporter to the painting shop where their surfaces are blasted and painted with 3～6 coats of paint. The joints between the blocks are welded at the dock before the final coat of paint is applied. Our four large-scale painting shops use eco-friendly paint that provides highly effective anti-corrosion coating to prolong the life of a ship without any impact on the human body.

The 6th Process

Erection

This is a process where the blocks assembled and painted are shaped into a ship. At the outdoor assembly yard near the dock, several small blocks are joined into a large block which are stacked in the dry dock and then welded to form a complete ship shape. To build a 300,000-ton oil carrier, 120 small blocks are assembled into 80 large blocks of 40 m in length and width and 780-ton weight. The large blocks are lifted and stacked by a 900-ton Goliath crane, which is a technology that gives us a high competitiveness in building ships and offshore plants.

The 7th Process

Launching

This is a process where a completed ship is moved into the water. When the final coat of paint is applied to the ship after the body blocks, cabins, the main engine and propellers are installed, the dock is flooded to float the ship. When the dock is filled with water, the dock gate is opened, and the ship is moved to a quay wall by a tugboat for the finishing touches. Using our thorough process management, 95% of the shipbuilding is completed by the time the launching begins after the scaffoldings are removed and the generator and boilers are on.

The 8th Process

Outfitting

This is a process where mechanical devices, piping and wiring are fitted and checked. Installation of the engine and boiler on the pre-installed mounts and fitting the engine room equipment and wiring, which started at the outdoor assembly yard and the dock, are finished at the quay wall after the launching. We ensure the fitting-out is 90% completed before the launching when it provides better working conditions to maintain high outfitting quality.

The 9th Process

Sea Trial

This is a process to test the ship's performance and seaworthiness while sailing. Once the power is connected to the installed mechanical equipment such as the main engine, generator, boiler and loading equipment at the quay wall, a test operation is done. Then, the ship is taken to the open sea for a sea trial under the real sailing conditions. In this process, all the performance and seaworthiness of the ship are checked against the contract and the designs in the presence of the ship-owner and inspectors.

The 10th Process

Naming & Delivery

When the ship is completed, the shipyard holds a naming ceremony for the new ship. Women nominated by the ship-owner christen the ship which will then become an official carrier in the register. After the delivery document to hand over ownership to the owner is signed by both parties, the ship starts its full-scale voyage. We provide after-sales services in order to guarantee the quality of the ship for a full year after the delivery.

Build a plant

The 1st Process

Engineering & Design

This is a design process where the structure, shape, and detailed building plans are created after the type of the offshore plant is decided according to the depth of the ocean, weather conditions, and amount of oil in the underwater reserve. During the detailed design process, the size, capacity, facilities and mechanical equipment needed are determined depending on the size of the oil or gas reserves. About 500 professional design engineers at Shipyard who are specialized in offshore plants create both the detailed design and production design, and the customer and production requirements are reflected in design stages already using simulation.

The 2nd Process

Steel Cutting

This is the process of cutting steel plates according to the designs. The steel plates are coated with anti-corrosive paint and moved to the cutting shop on the conveyor. Based on the design information sent to a computer, the steel plates are cut into shapes by the fully automatic cutting machines. The steel plate cut-outs with individually assigned ID numbers are moved to applicable assembly processes for each product.

The 3rd Process

Assembly

This is a process to manufacture a deck where the offshore facilities will be mounted for oil and natural gas production. On the steel plates, main aggregates and right and left frames are added, and the main columns and coaming stiffeners are installed. The completed deck is moved on a transporter to the offshore plant outdoor assembly yard.

The 4th Process

Pre-Outfitting

This is a process to install the pipes and electrical wires that cross under the deck while it is up side down. Working on the turned-over deck is easier for the workers, thereby increases productivity and accuracy. Also, the unique outfitting technology of manufacturing in a bundle and inspecting by area ensures high outfitting quality.

The 5th Process

Painting

This is a process where the manufactured deck module is moved on a transporter to the painting shop to be painted with about 4 coats of paint.   The surfaces of the welding parts and joints are shot blasted to increase anti-corrosion protection before being painted.

The 6th Process

Hinge Turnover

This is a process where the painted deck module is fixed at one side with a hinge and then turned over by a crane. For a deck that weighs under 400 tons, a crawler crane is used at the offshore plant assembly yard, and for a deck over 400 tons, a 900-ton Goliath crane is used.

The 7th Process

Fabrication of Machinery

On the deck sitting upright, various mechanical equipment needed for drilling and production, such as a compressor and a generator are bundled to be erected and installed.   They are fabricated into sizes that can be lifted by a crawler crane or offshore crane and installed one by one.

The 8th Process

Launching & Transfer

This is a process where the floating structure built along the commercial production line at the Dock 1 is launched and moved to the loading quay wall while a deck module is manufactured.   We manufacture high quality floating structures with the world's foremost structure block fabrication and building technology.

The 9th Process

Block Fabrication

This is a process where the prefabricated deck module is mounted on the floating structures in the water using a 2000～3000-ton offshore crane.   Since the fabricated modules are erected after the outfitting is almost completed, all there is to do to complete a ship is connecting the joints.

The 10th Process

Sea Trial & Delivery

This is a process where each equipment is put to the test in an actual trial run in the presence of the owner and inspectors. The positioning device, drilling equipment, production and compression, processing, and loading facilities are put into full operation that mimics an actual offshore situation. After the trial run, We deliver the plant to a yard or local installation site designated by the contract and provides after-sales services for a full year as a way to guarantee its quality.