Method for building a container ship with the hatch coaming and the upper deck, the side, the transverse bulkhead, the box column and the rail structure combined

Abstract

This invention discloses a construction process for container ships, involving the assembly and placement of the hatch coaming, upper deck, sidewalls, transverse bulkheads, column structures, and guide rails onto a fixed platform. To address the problems of traditional processes, such as numerous sections and mounting units, large amounts of dock welding and painting, difficulty in precision control, extensive high-altitude work, high costs, and long cycles, this invention first completes the hatch coaming and upper deck mid-assembly separately, then assembles the deck mid-assembly sections; using the sidewall plating as a reference, it assembles and paints the large deck sections; finally, it uses a fixed platform in the field to combine these sections with the sidewall plating, transverse bulkheads, column structures, and guide rails to form mounting units, which are then flipped and loaded into the dock. This invention moves the process forward, reducing crane usage time, improving construction precision, lowering the risks of high-altitude work, reducing paint burn, shortening the dock cycle, and significantly reducing shipbuilding costs.

Description

Technical Field

[0001] This invention relates to a construction process for assembling and mounting container ship hatch coaming, upper deck, sides, transverse bulkheads, column and guide rail structure, which belongs to the field of shipbuilding technology. Background Technology

[0002] Traditional container ship construction processes involve either integrating the upper deck and sides into a single unit, while fabricating and installing the hatch coaming and side bulkheads separately; or integrating the hatch coaming with the upper deck and side structures, while fabricating and installing the side bulkheads and side bulkheads separately.

[0003] The aforementioned construction methods involve a large number of sections and units, prolonged crane usage, and a significant proportion and quantity of thick outer plating, main deck, and hatch coamings. This results in a massive amount of welding work in the dry dock after assembly, making it difficult to control manufacturing precision. Furthermore, the large areas of paint burn-off lead to poor paint integrity in compartments, requiring substantial touch-up painting. These factors impact the dry dock cycle and construction pace. Additionally, the increased use of high-altitude work during welding and painting necessitates additional scaffolding or the use of elevated work platforms, leading to high safety risks and a sharp increase in shipbuilding costs. Summary of the Invention

[0004] To address the problems of traditional construction methods involving multiple sections and mounting units, extensive dock welding and painting work, difficulty in controlling construction precision, high-altitude operations, high safety risks, and long crane usage time, which lead to long dock cycles and high shipbuilding costs, this invention provides a pre-assembly construction process for container ships, which involves assembling the hatch coaming, upper deck, sides, transverse bulkheads, column, and guide rail structure. This pre-assembly process reduces the use time of gantry cranes, shortens the dock cycle, and improves operational efficiency. Simultaneously, it reduces on-site construction difficulty and allows for better control of manufacturing precision.

[0005] The technical solution adopted in this invention is: a construction process for assembling a container ship hatch coaming with the upper deck, sides, transverse bulkheads, column and guide rail structure, comprising the following steps: S1. The hatch coaming is constructed first to form the hatch coaming mid-section assembly, and the upper deck is constructed first to form the upper deck mid-section assembly. Then, using the longitudinal bulkhead as the base plane, the hatch coaming mid-section assembly, the upper deck mid-section assembly, the longitudinal bulkhead structure, and the internal substructure are combined to form the deck mid-section segment. After the deck mid-section segment is turned 180 degrees using a crane, it is assembled in the workshop using the side outer plating as the base plane to form the main deck segment. The specific steps include the following: S1.1 Assemble the hatch coaming in advance: Using the inner side plate as the base plane, after the inner side plate is assembled, the side plate ribs and outer side plates are arranged in sequence, and then welded after assembly; after turning it 180 degrees with a crane, it is closed to the top plate for welding. S1.2 Assembly of the upper deck: Using the upper deck as the base plane, the panels are assembled and automatically welded. The installation positions of the upper deck keel and upper deck ribs are marked on the marked plane. The upper deck keel and upper deck ribs are configured in sequence. The assembly is carried out in a horizontal operation and then welded. S1.3, Assemble the deck into sections: S1.31. Using the longitudinal wall as the BASE reference plane, the longitudinal wall is first spliced ​​and automatically welded and then installed on the jig. The longitudinal wall ribs are marked and configured. S1.32. The upper deck advance assembly is configured on the side of the longitudinal bulkhead, and horizontal operation is carried out for assembly; S1.33. Hoist all the outer plate ribs and insert them into the longitudinal wall ribs and upper deck ribs for welding; S1.34. The hatch coaming advance mid-mounted assembly is configured and welded on the side of the deck advance mid-mounted assembly; S1.4 Deck section construction: Using the outer side plating as the base plane, the outer side plating is assembled, automatically welded, and marked; the middle deck sections are assembled by using a crane to rotate 180 degrees and then joined together for horizontal operation; the inner longitudinal wall structure is then assembled and welded, inspected, and moved out of the assembly workshop; and then painted in the painting workshop to complete the construction of the deck section. S2. Using the outer side plating as the base plane, several large deck sections, several large outer side plating sections, several large transverse bulkhead sections, several box column structures, and several guide rail structures are combined into an assembly unit; a gantry crane is used to transport the assembly to the dry dock; specifically, the following steps are included: S2.1. Several sections of the outer side plating are assembled in the field to obtain the complete outer side plating section; S2.2. Several deck sections and the outer side plating sections are joined together in the field to obtain the deck outer side plating sections; S2.3. Several transverse bulkhead sections are joined with the deck side outer plating section in the field to obtain the deck side outer plating transverse bulkhead section. S2.4. Several box column structures and the deck side outer plate transverse bulkhead section are assembled in the field to obtain the deck side outer plate transverse bulkhead box column section. S2.5, Several guide rail structures and deck side outer plating transverse bulkhead column sections are assembled in the field. S2.6. Carry out painting and touch-up painting operations. After the operation is completed, use a gantry crane to turn the ship 90 degrees to its normal state and then go to the dock to assemble it.

[0006] Furthermore, in step S1.2, anti-tipping braces are installed on the side near the longitudinal bulkhead when the upper deck ribs are configured; the anti-tipping braces are removed after the upper deck is pre-assembled in step S1.32.

[0007] Furthermore, in step S1.34, after the hatch coaming is assembled, it is fixed with a tire frame, and reinforcement is provided on the inner side of the TOP plate to prevent welding deformation.

[0008] Furthermore, in step 1.4, when welding the inner structure of the assembled longitudinal wall, the inner fillet welds of the hatch coaming intermediate assembly and the upper deck intermediate assembly are welded simultaneously.

[0009] Furthermore, the transverse bulkhead segment includes watertight bulkhead segments and structural bulkhead segments.

[0010] Furthermore, in step S2.5, the guide rail structure cannot be assembled in the large assembly stage; the guide rail structure that can be assembled in the large assembly stage is integrated with the watertight compartment section and the structural bulkhead section.

[0011] Compared with the prior art, the present invention has the following advantages: 1. By streamlining the process before it begins, the usage time of the gantry crane is reduced, the dry dock cycle is shortened, and the operational efficiency is improved. 2. It reduces the difficulty of on-site construction and allows for better control of manufacturing precision; all segmented structural welding is done in the downward and vertical directions, avoiding a large amount of overhead welding, improving on-site welding conditions, and enhancing welding quality and work efficiency. 3. Reduce paint burn damage at the connection between hatch coaming and upper deck. Paint damage and related repair work at the connection between hatch coaming and upper deck structure, transverse bulkhead and side plating longitudinal bulkhead structure, box column and upper deck structure, and guide rail and transverse bulkhead structure are all completed in the painting workshop or during the pre-shipment setup stage, greatly improving the work completion rate; 4. The original high-altitude welding and painting reinforcement work were all completed at heights, while the new construction process is completed entirely at a flat or low level, which greatly reduces the safety risks of on-site operations and inspections, and significantly improves the completion rate of painting. 5. Shipbuilding costs have been significantly reduced. Attached Figure Description

[0012] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0013] Figure 1 This is a schematic diagram illustrating the construction process. Figure 2 A schematic diagram of the hatch coaming pre-assembly assembly; Figure 3 This is a schematic diagram of the upper deck being assembled first. Figure 4 This is a schematic diagram of the deck midsection sections; Figure 5 This is a side view of the deck's midsection sections; Figure 6 This is a schematic diagram of the deck sections. Figure 7 This is a schematic diagram of the mounting unit; Figure 8 This is a schematic diagram of the mounting unit (ship in normal condition).

[0014] In the picture: 1. The deck is divided into sections; 11. Hatch coaming intermediate assembly; 111. Inner side panel; 112. Side panel rib; 113. Outer side panel; 1131. Waist frame; 114. TOP panel. 12. Upper deck first mid-section, 121. Upper deck, 122. Upper deck keel, 123. Upper deck rib; 13. Longitudinal wall; 131. Longitudinal wall rib; 132. Inner structure of longitudinal wall; 2. The outer side plating is divided into sections; 21. The outer side plating; 211. The outer plating ribs. 3. Transverse bulkhead sections; 31. Structural bulkhead sections; 32. Watertight bulkhead sections; 4. Box-column structure; 5. Guide rail structure. Detailed Implementation

[0015] Ship hull construction follows a hierarchical decomposition logic of "parts → sub-assembly → mid-assembly → large assembly → section → final assembly → hull assembly". The specific sequence and process for the assembly of large sections during the final stage are as follows: S1. Assemble the hatch coaming in advance: S1.1. Taking the inner side plate as the base, the inner side plate is assembled → the side plate ribs are configured → the outer side plate is configured → the plate is removed and then welded. S1.2, After using a crane to flip it over, assemble it into the TOP plate → weld → inspect → move it out; S1.3, Join the sections of the deck midships; S2. Assemble the upper deck first: S2.1 The above deck is BASE. Mark the panel assembly → automatic welding → mark the line → configure the upper deck keel → configure the upper deck rib plate → horizontal operation → removal → welding → inspection → removal. S2.2, Join the sections of the deck midships; S3, Assembled deck sections: S3.1. Taking the inner side of the longitudinal wall structure as the base, first assemble the panels → automatic welding → install the jig on the longitudinal wall structure → mark the lines → configure the longitudinal wall ribs. S3.2, Upper deck pre-assembly → Horizontal operation → Retrieval and delivery; S3.3, All outer panel reinforcing bars are hoisted and welded; S3.4. Hatch coaming assembly → welding → inspection → removal; S4. Deck sections are constructed in sections: S4.1. Using the outer side plating as the base, assemble the outer side plating → automatic welding → marking; S4.2, Deck midsection sectional assembly → Horizontal operation; S4.3, Assemble the inner structure of the longitudinal wall → Weld → Inspect → Remove; S4.4, Painting in the painting workshop; In the above process, all segmented structural welding was carried out in the downward and vertical directions, avoiding a large amount of overhead welding, improving on-site welding conditions, improving welding quality and work efficiency, and reducing paint burn at the connection between the hatch coaming and the upper deck.

[0016] S5, Unit Construction: S5.1. Taking the outer side plating as the base, multiple deck sections, multiple outer side plating sections, multiple transverse bulkhead sections (including watertight bulkhead sections and structural bulkhead sections), multiple box column structures and multiple guide rail structures are combined to form an assembly unit. S5.2. Use a gantry crane to turn the ship 90 degrees to its normal position and then load it into the dock.

[0017] Furthermore, S2.1 When configuring the upper deck ribs, anti-tipping diagonal braces should be installed on the side near the longitudinal bulkhead, and removed after the middle assembly is assembled.

[0018] Furthermore, S3.1 After the hatch coaming is assembled, it is fixed with a tire frame. The TOP plate and the inner side of the hatch coaming are reinforced to prevent welding deformation. Example 1

[0019] like Figure 1As shown, this process involves assembling the hatch coaming pre-assembly 11, the upper deck pre-assembly 12, and the longitudinal bulkhead 13 to form a deck mid-section. After the deck mid-section is flipped over, it is then assembled with the side outer plating 21 as the reference surface to form a large deck section 1. After the large deck section 1 is moved out of the assembly workshop, multiple large deck sections 1, multiple side outer plating sections 2, multiple transverse bulkhead sections 3 (watertight bulkhead section 31, structural bulkhead section 32), multiple box column structures 4, and multiple guide rail structures 5 are assembled in the field to form a super-large section (mounted unit). After the mounted unit is painted and touched up, it is flipped 90 degrees to the ship's normal state using a gantry crane and then assembled in the dry dock (mounted).

[0020] Specifically, the following steps are included: S1, Assemble the hatch coaming preliminary group 11 (such as...) Figure 2 ): S1.1. Using the inner side plate 111 as the base, complete the assembly of the inner side plate 111; then, sequentially configure the side plate ribs 112 and hoist the outer side plate 113. After completing the component positioning and installation, proceed with the welding operation. S1.2. Using a crane, the above-mentioned assembly is flipped over and joined to the TOP plate 114 for welding to obtain the hatch coaming intermediate assembly 11.

[0021] S2, Assemble the upper deck pre-assembly (e.g.) Figure 3 ): S2.1. Using the above deck 121 as the BASE reference, after completing the splicing and automatic welding, the lines are drawn; the upper deck keel 122 and the upper deck rib 123 are configured in sequence; when configuring the upper deck rib 123, anti-tipping diagonal bracing is added on the non-upper deck side (i.e. the side close to the longitudinal bulkhead), and it is removed after the middle assembly is assembled; horizontal operation and welding are carried out to obtain the upper deck preliminary middle assembly 12.

[0022] S3, Assembled deck sections (such as...) Figure 4 and Figure 5 ): The hatch coaming pre-assembly 11, the upper deck pre-assembly 12, the longitudinal bulkhead rib 131 structure, and the longitudinal bulkhead 13 are assembled and constructed as a single unit in the assembly workshop to form the deck midship section: S3.1. Using the longitudinal wall 13 as the base, after completing the splicing and automatic welding, the frame 1131 is installed; after completing the marking, the longitudinal wall ribs 131 are configured; after the hatch coaming intermediate group 11 is closed, it is fixed by sealing the frame 1131, and a reinforcing member is added at the contact position between the TOP plate 114 and the inner side of the hatch coaming intermediate group 11 to prevent welding deformation. S3.2, hoist the first assembly 12 onto the upper deck to complete horizontal operations and component delivery; S3.3 Hoist the outer panel reinforcement 211 and weld it to ensure structural strength during segmented hoisting and transportation, and control installation accuracy; S3.4. Precisely configure the hatch coaming pre-assembly group 11, complete the welding of the flat fillet welds and the large group welding of the overhead fillet welds, and after passing the precision inspection, move the deck mid-assembly group out of the work area as a whole.

[0023] S4, Deck section 1 construction (e.g.) Figure 6 ): S4.1. Using the side outer plating 21 as the BASE reference, complete the splicing, automatic welding and marking of the side outer plating 21. S4.2. Join the deck midsection sections completed in S3 with the side outer plating 21 and perform horizontal alignment. S4.3 Assemble the inner structure 132 of the longitudinal wall and complete the welding (including the inner fillet weld of the hatch coaming intermediate group 11 and the upper deck intermediate group 12). After the accuracy inspection is qualified, move the deck section 1 out as a whole. S4.4. Send the deck section 1 to the painting workshop to complete the overall painting operation.

[0024] S5, Construction of mounting units (such as...) Figure 7 and Figure 8 ): After the deck section 1 is moved out of the assembly workshop for painting, S5.1. Using the outer side plating 21 as the BASE reference, on the field positioning platform, multiple deck sections 1, outer side plating sections 2, transverse bulkhead sections 3 (including structural bulkhead sections 31 and watertight bulkhead sections 32), box column structure 4, and guide rail structure 5 are precisely combined to form a complete mounting unit. S5.2 After completing the painting and touch-up work on the mounting unit, use a gantry crane to turn it 90° to the ship's normal posture and transfer it to the dock to complete the final mounting and assembly.

[0025] The purpose of hoisting all the outer panel reinforcing bars 211 is to ensure the strength of the middle section frame structure, to ensure that the middle section structure does not deform during hoisting and transportation, and to control the dimensional accuracy of each structure during installation. Pre-assembly is a subdivided stage in the mid-assembly phase, representing a refined process arrangement in modern shipbuilding's mid-assembly stage. Specifically, for complex multi-system components, the assembly process is broken down into multiple sequential stages. The first stage (pre-assembly stage) is completed first, followed by subsequent stages, ultimately forming a complete mid-assembly unit. It is a concrete application of the hull-based segmented operation method and the intermediate product-oriented model, with its core being the realization of process decomposition, rhythmic production, and optimized resource allocation.

[0026] In the indoor assembly workshop, the process of assembling small sections into larger sections / complete sections is called assembly workshop joining. It is a core preliminary process before dock joining and field assembly.

[0027] The outdoor assembly process is the core final assembly technology in modern shipbuilding. In the open-air assembly area (outdoor area) outside the slipway / dock, the prefabricated hull sections are precisely welded into large ring sections / three-dimensional sections according to the hull lines on fixed positioning platforms (plates), and then transported as a whole to the dock to complete the final assembly.

[0028] Using off-site betting has the following advantages: 1. Release dock capacity: The dock is only responsible for final assembly, while the field assembly is carried out in parallel, which greatly shortens the dock cycle (the dock turnover rate is increased by 30%-50%).

[0029] 2. Improved construction precision: Construction on a fixed platform ensures uniformity of reference and controllable deformation, with overall section precision reaching the millimeter level, reducing the difficulty of dock assembly.

[0030] 3. Improved working environment: The open-air site facilitates the operation of large lifting and transportation equipment, and makes processes such as segmented turning, welding, and painting more efficient.

[0031] 4. Enable parallel engineering: The overall construction cycle is shortened by having the field assembly, dock installation, and workshop segment prefabrication work proceed in parallel.

[0032] In summary, this construction process reduces docking time, improves operational efficiency, and simplifies on-site construction. Paint damage and related repair work at the connections of hatch coamings and upper deck 121, transverse bulkhead section 3 and side plating section 2, box column and upper deck 121, and guide rail and transverse bulkhead are all completed in the painting workshop or before construction, significantly improving work completion. Previously, high-altitude welding and paint repair were performed at heights; the new construction process completes all work at a horizontal or low level, greatly reducing safety risks during on-site operations and inspections. The significantly improved painting completion rate greatly enhances owner satisfaction.

[0033] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for building a container ship with the hatch coaming and the upper deck, the side, the transverse bulkhead, the box column and the rail structure after the closing of the deck, the side, the transverse bulkhead, the box column and the rail structure, characterized in that, Includes the following steps: S1. The hatch coaming is constructed first to form the hatch coaming intermediate assembly (11), and the upper deck is constructed first to form the upper deck intermediate assembly (12). Then, with the longitudinal bulkhead (13) as the base plane, the hatch coaming intermediate assembly (11), the upper deck intermediate assembly (12), the longitudinal bulkhead structure, and the internal sub-structure are combined to form the deck intermediate assembly section. After the deck intermediate assembly section is turned 180 degrees by a crane, it is assembled in the workshop with the side outer plating (21) as the base plane to form the deck major assembly section (1). Specifically, the following sub-steps are included: S1.1 Assemble the hatch coaming first (11): Using the inner side plate (111) as the BASE reference plane, after the inner side plate (111) is assembled, the side plate ribs (112) and the outer side plate (113) are arranged in sequence, and then welded after assembly; after the crane is turned 180 degrees, it is joined to the TOP plate (114) for welding. S1.2, Assemble the upper deck first group (12): Using the upper deck (121) as the BASE reference plane, draw lines on the surface to splice the plates and weld them automatically. Draw lines on the surface to indicate the installation positions of the upper deck keel (122) and upper deck rib (123). Arrange the upper deck keel (122) and upper deck rib (123) in sequence. Perform assembly in a horizontal operation and weld after assembly. S1.3, Assemble the deck into sections: S1.

31. Using the longitudinal wall (13) as the BASE reference plane, the longitudinal wall (13) is first assembled and automatically welded and then installed on the jig (1131). The longitudinal wall (13) is marked with the longitudinal wall ribs (131) and the longitudinal wall ribs (131) are configured. S1.

32. The upper deck advance mid-assembly (12) is arranged on the side of the longitudinal wall (13), and horizontal operation is carried out for assembly; S1.33, hoist all the outer plate ribs (211) and insert them into the longitudinal wall ribs (131) and the upper deck ribs (123) for welding; S1.34, The hatch coaming advance mid-mount (11) is configured and welded on the side of the deck advance mid-mount (12); S1.4 Construction of the deck section (1): Using the side outer plating (21) as the BASE reference plane, the side outer plating (21) is automatically welded and marked after splicing; the deck midsection is assembled by using a crane to turn it 180 degrees and then join it together for horizontal operation; the inner structure of the longitudinal wall (132) is then assembled and welded, inspected and moved out of the assembly workshop; it is then painted in the painting workshop to complete the construction of the deck section (1); S2. Using the side plating (21) as the base plane, several deck sections (1), several side plating sections (2), several transverse bulkhead sections, several box column structures (4), and several guide rail structures (5) are combined into a loading unit; a gantry crane is used to load the equipment into the dry dock; the specific steps include: S2.1, Several sections of the outer side plating are assembled in the field to obtain the complete section of the outer side plating; S2.2, Several deck sections (1) are joined with the outer side plating section in the field to obtain the outer side plating section of the deck; S2.

3. Several transverse bulkhead sections are joined with the deck side outer plating section in the field to obtain the deck side outer plating transverse bulkhead section. S2.4, Several box column structures (4) are joined with the deck side outer plate transverse bulkhead section outside the field positioning plate to obtain the deck side outer plate transverse bulkhead box column section; S2.5, Several guide rail structures (5) are joined with the deck side outer plate transverse bulkhead column section field positioning plate. S2.

6. Carry out painting and touch-up painting operations. After the operation is completed, use a gantry crane to turn the ship 90 degrees to its normal state and then go to the dock to assemble it.

2. A method of building a container ship with the hatch coaming and upper deck, side, transverse bulkhead, corner post and rail structure assembled on a bed plate, as claimed in claim 1, wherein: In step S1.2, when the upper deck rib (123) is configured, anti-tipping bracing is set on the side near the longitudinal bulkhead; the anti-tipping bracing is cut off after the upper deck intermediate assembly (12) is assembled in step S1.

32.

3. A method of building a container ship with the hatch coaming and upper deck, side, transverse bulkhead, corner post and rail structure assembled on a bed plate, as claimed in claim 2, wherein: In step S1.34, after the hatch coaming intermediate assembly (11) is closed, the tire frame (1131) is used to seal and fix it. The TOP plate (114) and the inner side of the hatch coaming are reinforced to prevent welding deformation.

4. The construction process for a container ship hatch coaming, upper deck, sides, transverse bulkheads, column and guide rail structure as described in claim 3, characterized in that: In step 1.4, when welding the inner structure (132) of the longitudinal wall, the inner fillet welds of the hatch coaming intermediate group (11) and the upper deck intermediate group (12) are welded at the same time.

5. The construction process for assembling and mounting container ship hatch coaming, upper deck, sides, transverse bulkheads, column and guide rail structure as described in claim 4, characterized in that: The transverse bulkhead is divided into watertight bulkhead sections (32) and structural bulkhead sections (31).

6. The construction process for assembling and mounting container ship hatch coaming, upper deck, sides, transverse bulkheads, column and guide rail structure as described in claim 5, characterized in that: In step S2.5, the guide rail structure (5) cannot be assembled in the large assembly stage; the guide rail structure (5) that can be assembled in the large assembly stage is integrated with the watertight compartment section (31) and the structural bulkhead section (32).

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