The Goliat-Docklift system - TTS Group ASA

The Goliat-Docklift system
– an innovative approach to boosting shipbuilding capacity
By Rolf-Atle Tomassen – Managing director TTS Handling Systems
As the world’s shipbuilding industry enjoys full order books,
capacity is a scarce resource. How then can shipyards profi t
from this market opportunity without making huge investments
in new building docks and goliath cranes?
An innovative - yet simple approach is to build bigger and
therefore fewer ship blocks. The effect of this is reduces
working hours in the dock and hence an increases through put.
This approach not only boosts capacity – it increases productivity
as well.
The challenge is how to cost effectively implement this
approach.
When designing a shipyard, a building dock is often the
single largest investment. In order to optimise this investment
– it is designed with a capacity cap. This is fi ne looking at the
case with investment eyes, however, looking at the potential
for increasing capacity – this view effectively stops any
GLOBAL TRENDS IN SHIPBUILDING THROUGHOUT THIS CENTURY
increase in shipbuilding capacity – and therefore an increase in
income/profi ts.
Some 30 years ago it was not unusual to assemble ships
from 30-50 ton blocks. As the time in dock is virtually proportional
to welding metres – this method required plenty of
dock time. As the size of ship blocks has increased to typically
300-600 tonnes - dock assembly time has been dramatically
reduced - some shipyards reaching a 4-8 week launch cycle.
Some shipyards are already thinking and implementing an even
larger block-building method involving block up to 1.200 tonnes
– even 2.000 tonnes. Not surprisingly – these are Japanese
and South Korean shipyards. Examples of this include: South
Korea’s Hanjin Shipyard, which is planning to increase its lifting
capacity to 2.000 ton; and Japan’s Namura Shipbuilding,
which will also increase its block lifting capacity – with a goal
of increasing productivity, and reducing time

The Goliat-Docklift system
in dock from 29 to 21 days, hence increasing the number of
ships built each year from 8 to 12.
One of the reasons to why this has not been done to a
greater extent – is the cost of getting the necessary 1.200 or
2.000 tonnes lifting capacity. Technology such as the goliath
crane – has its optimum working range. Imagine the cost
of a 2.000 tonnes goliath crane spanning some 140 metres.
Another reason is probably the general shipyard conservative
view of new technology.
When increasing a shipyard’s capacity by utilising block
building weighing 1.200-2.000 tonnes, the Goliat Docklift
concept is the only cost viable alternative.
The concept comprises a Docklift and a heavy load/fl exible
fl uid bed transporter – a Dual Walking Beam (DWB).
The DWB transporters, which have lifting capacities of 100,
200 and 400 tons units, transport the block from the block
assembly area to the building dock and the Goliat Docklift.
The Goliat Docklift, which is similar in operation to shiplifts,
then lowers the block into the building dock.
From here – the DWB walks the block to the ship and
accurately positions the block in six axes.
The system has already made its mark in a few shipyards – the
largest installation being at Zaliv Shipyard, Ukraine. Here TTS
has delivered a 2.000 tonne capacity Docklift and 10 DWBs of
200 tonne capacity each. Meanwhile, France’s largest naval
shipyard, DCAN, Cherbourge has a total of 38 DWBs of up to
400 tonnes capacity each. Other shipyards using TTS DWBs
as part of the production system, include the Norwegian
ship yards – Bomek, Ulstein, Kvaerner Fjellstrand, Kvaerner
Mandal, and Sterkoder, Bazan (Spain), Kvaerner (Singapore)
and Marinette Marine (US).
The DWB can transport blocks – or if necessary complete ships.
The Goliat Docklift – inside the building dock