The problem is of course that labour is pretty expensive at home in Norway, and cost savings are the order of the day. So, yards like Ulstein tend to ship in modularised sections for assembly in Norway \u2013 but of course the inexorable rise in technology has an impact on the whole build process.<\/p>\n
The weight itself is nothing to be sneezed at. Since completed ships like the Ulstein\u2019s 130m SX121 design are around 10,750dwt in total, it\u2019s not uncommon for the fully outfitted individual modules to weigh in at over 500 tonnes, explains Jonn Gunnar Bj\u00f8rkedal of Ulstein.<\/p>\n
Further, he explains that there\u2019s a different economic outline to each one as with each contract you are looking at a different argument for each yard: \u201cCost levels fluctuate a lot with these builds so it is a complicated picture; but yard capacity, time schedule and prices make the decision as to what gets constructed where.\u201d<\/p>\n
Interestingly, he points out that Ulstein is now trying to do more of its complicated engineering in Norway itself. However it remains a fact that most of the large steel sections are still either shipped in from the Ukraine or from Gdynia in Poland, ready to be matched with their siblings when they finally come home.<\/p>\n
For example, a very recent build saw the Polish Crist yard handling some of the larger steel parts including the whole aft of the ship while the Norwegian yard took on the more outfitted areas of the foreship including the complicated engine section and wheelhouse.<\/p>\n
It\u2019s fairly obvious that building like this does create some issues, he admits. To start with, \u201cyou have to be pretty certain of your tolerances\u201d but the logistics side presents its own challenges. This leaves Mr Bj\u00f8rkedal co-ordinating a very intricate dance to bring the sections together.<\/p>\n
Mr Bj\u00f8rkedal explains \u201cit\u2019s not just the steel\u2019s weight that makes a difference\u201d to the logistics process. There are particular issues inherent in the design that makes handling tricky: after all, most of them have compound curves running in three dimensions and moreover, many of them are pre-engineered and outfitted, which adds to their vulnerabilities.<\/p>\n
Further, unlike most builds, even when assembled these modules are not designed simply to \u2018stand up\u2019 on land but to float, adding another set of stresses to the calculations. Much of the answer lies in the tailor-made steel cradles that are designed to spread the load both across the deck and relieve the high pressure points on these curved modules, but there\u2019s no \u2018one size fits all\u2019 solution as, again, they are different for every type of build.<\/p>\n
On top of this, the journey itself from the two main yards back to Norway present a challenge. Bringing the hull from the Ukraine takes a month: \u201cYou have to tow the hull all the way through the Med, through the channel, and up through the Bay of Biscay which can have bad weather during winter time, so that can delay things too.\u201d On the other hand he adds that the module and hull transports from Gdynia also have some challenges, \u201cbut at least this is shorter as it simply comes out through the Baltic and takes around a week\u201d.<\/p>\n
Once the sections are offloaded in Ulsteinvik some \u2013 often the more complex variety \u2013 receive their main outfitting and gain a huge slab of equipment in the process. For example the engine modules are brought in using SPMT multiwheelers for transport into the dock hall followed by using Ulstein\u2019s two, 250 tonne capacity dock hall cranes to lift the modules down on to the dock bed. Then they are packed chock-full of sophisticated and somewhat sensitive gear; it isn\u2019t unusual for these modules to more than double in weight before the final lift.<\/p>\n
Seeing it from some distance, the \u2018dance\u2019 that brings these structures together in the tight yard space at Ulstienvik is intricate enough. Seen up close, you have to admire the management of these huge, complicated logistics both in and out of the yard.<\/p>\n
A round of applause for choreographer Mr Bj\u00f8rkedal, if you please.<\/p>\n
Flexing the muscle<\/b><\/p>\n