NAME -499
Shipyard Management
Conducted By:
Cdr Ehtasham Ahmed Quraishi, (E), BN
DESIGN AND PROCESS ALTERNATIVES BETWEEN BLOCK
CONSTRUCTION AND TRADITIONAL KEEL LAY CONSTRUCTION
IN SHIPBUILDING
In shipbuilding, two primary methods of construction are often
compared: traditional keel-laying construction and block construction
(modular construction). Evaluating these involves considering design
flexibility, efficiency, cost, quality control, scheduling, and logistics.
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DESIGN AND PROCESS ALTERNATIVES BETWEEN BLOCK
CONSTRUCTION AND Accidents
A Shipyard TRADITIONAL KEEL LAYinCONSTRUCTION
Analysis Egypt
IN SHIPBUILDING
Design and Engineering Flexibility
Traditional
Aspect Block Construction
Construction (Keel Lay)
High – ships are designed
Low – design must follow
in blocks/modules that
Design Modularity a sequential structure
can be independently
from keel up
designed and engineered
Allows parallel design and Limited; one part must be
Parallel Design
planning of multiple finished before the next
sections starts
More adaptable to design Less flexible once keel is
Flexibility
changes in later stages laid and structure
progresses
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DESIGN AND PROCESS ALTERNATIVES BETWEEN BLOCK
CONSTRUCTION AND Accidents
A Shipyard TRADITIONAL KEEL LAYinCONSTRUCTION
Analysis Egypt
IN SHIPBUILDING
Production Efficiency
Traditional
Aspect Block Construction
Construction
Parallel production of Sequential – structure
Workflow blocks (hull, must be built from the
superstructure, engine keel upward
room, etc.)
Significantly reduces total Slower – all work must
Time Efficiency
build time due to parallel follow a sequence
work
Outfitting (pipes, Limited pre-outfitting
Pre-outfitting
machinery, wiring) can be possible
done inside blocks before
assembly 5
DESIGN AND PROCESS ALTERNATIVES BETWEEN BLOCK
CONSTRUCTION AND Accidents
A Shipyard TRADITIONAL KEEL LAYinCONSTRUCTION
Analysis Egypt
IN SHIPBUILDING
Quality Control and Inspection
Aspect Block Construction Traditional
Construction
Better – easier to inspect Difficult – access becomes
Inspection Accessibility and correct blocks before limited as the structure is
final assembly built
Challenging on the main
Easier in workshop
Welding and Fit-Up hull, especially in tight
conditions
areas
Easier to isolate and fix in More complex and costly
Rework
blocks in assembled structure
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DESIGN AND PROCESS ALTERNATIVES BETWEEN BLOCK
CONSTRUCTION AND Accidents
A Shipyard TRADITIONAL KEEL LAYinCONSTRUCTION
Analysis Egypt
IN SHIPBUILDING
Manpower and Skills Requirement
Traditional
Aspect Block Construction
Construction
Requires advanced Relies more on traditional
Skilled Labor planning and shipbuilding
coordination skills craftsmanship
High – more suitable for
Low – manual labor
Automation Potential automation and
intensive
mechanized production
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DESIGN AND PROCESS ALTERNATIVES BETWEEN BLOCK
CONSTRUCTION AND Accidents
A Shipyard TRADITIONAL KEEL LAYinCONSTRUCTION
Analysis Egypt
IN SHIPBUILDING
Cost Implications
Traditional
Aspect Block Construction
Construction
High – requires
investment in block
Initial Setup Cost handling cranes, large Lower initial investment
workshops, etc.
Lower in high-volume
Higher due to longer
production due to
Overall Cost build times and manual
economies of scale and
labor
time savings
Easier to estimate and Cost overruns more likely
Cost Control
control cost per block due to sequential
dependencies
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DESIGN AND PROCESS ALTERNATIVES BETWEEN BLOCK
CONSTRUCTION AND Accidents
A Shipyard TRADITIONAL KEEL LAYinCONSTRUCTION
Analysis Egypt
IN SHIPBUILDING
Project Scheduling and Delivery
Traditional
Aspect Block Construction
Construction
Better – modular Less control; delay in one
Schedule Control construction can follow phase affects all
tight project schedules subsequent steps
Faster – often used for Slower – suited to small-
Delivery Time
large series or naval ships scale or custom builds
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DESIGN AND PROCESS ALTERNATIVES BETWEEN BLOCK
CONSTRUCTION AND Accidents
A Shipyard TRADITIONAL KEEL LAYinCONSTRUCTION
Analysis Egypt
IN SHIPBUILDING
Facility Requirements
Traditional
Aspect Block Construction
Construction
Requires multiple
Needs basic slipway or
assembly shops, block
Infrastructure Needs dry dock for sequential
transport systems, and
build
heavy-lift cranes
Efficient – multiple blocks
Centralized work around
Space Utilization built simultaneously in
slipway or dock area
different locations
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DESIGN AND PROCESS ALTERNATIVES BETWEEN BLOCK
CONSTRUCTION AND Accidents
A Shipyard TRADITIONAL KEEL LAYinCONSTRUCTION
Analysis Egypt
IN SHIPBUILDING
Environmental and Safety Considerations
Aspect Block Construction Traditional Construction
Safer – more work done in Higher risk – work often at
Worker Safety controlled workshop heights or in confined ship
environments areas
Easier to manage Harder to control in large,
Environmental Impact emissions, noise, and open dock construction
waste in modular yards sites
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DESIGN AND PROCESS ALTERNATIVES BETWEEN BLOCK
CONSTRUCTION AND Accidents
A Shipyard TRADITIONAL KEEL LAYinCONSTRUCTION
Analysis Egypt
IN SHIPBUILDING
Conclusion
Criteria Best Suited Method
Mass Production Block Construction
Custom or One-off Ships Traditional Keel Lay
Time Efficiency Block Construction
Cost Efficiency (Large Scale) Block Construction
Low Capital Investment Traditional Keel Lay
High Quality Control Block Construction
For building multiple similar ships (e.g., naval ships, ferries, cargo vessels),
block construction is far more efficient and economical. For custom-built or
small-scale shipyards, traditional keel laying may still be appropriate due to
lower capital investment and flexibility with smaller teams. 12