Shipbuilding is no ordinary feat. It’s an art and science combined, where precision, expertise, and relentless planning transform raw materials into maritime giants. The journey from the first cut of steel to the grand unveiling of a new vessel involves far more than meets the eye. It’s a story of teamwork, cutting-edge technology, and an immense level of detail. Behind every successful ship launch, there’s a wealth of effort from diverse teams working in harmony. For Maersk, this process is undergoing a transformative shift to align with its green future goals, focusing on green methanol-powered vessels. But how does it all come together?
Mikkel Jacobsen, the Machinery Superintendent for Maersk, has a front-row seat to this extraordinary process. Based in South Korea, Mikkel joined the Maersk Site Team at Hyundai Heavy Industries (HHI) in Ulsan, where ships are brought to life. His role is essential, overseeing machinery integration for the fleet. As Mikkel explains, it all began with a monumental decision. “In March 2023, I moved with my family across the world. I had worked with Maersk for a decade, but this was a new challenge,” says Mikkel.
The process begins in the massive production halls of HHI, where the cutting of the first steel plate signals the start of construction. The steel cutting process, aided by laser-like gas flames, marks the birth of a new ship. For Mikkel and the team, this is just the beginning. As he describes it, “It’s like building with ‘Lego’ blocks, but these blocks are massive, and the stakes are high.”
Once the steel is cut, it is molded into enormous blocks, forming the structural foundation of the ship. These blocks are assembled with the utmost precision. Maersk’s structural team, the Hull Team, is responsible for ensuring that the steelwork adheres to the highest standards. After the steel blocks are built, they are coated with the iconic Maersk blue paint, a task that requires multiple tons of paint for the hull and intricate internal tank coatings.
While the painting team works on the aesthetic side, the machinery and electrical teams begin their crucial tasks. Every piece of equipment intended for the vessel is carefully tested and inspected. The ship’s heart – the main engine – is installed, and cables are carefully laid out. The moment the first block is lowered into the dry dock, known as ‘Keel Laying,’ the transformation takes a dramatic leap forward. From there, the ship starts taking shape rapidly, with thousands of tons of steel being added each day.
One of the most exciting moments comes when the ship is ready to be launched. The dry dock is flooded with thousands of liters of water every second, gradually lifting the vessel from its supports. It’s a dramatic and awe-inspiring sight. By the following morning, HHI’s powerful tugboats guide the vessel to the Outfitting Quay, where the finishing touches are made, and the ship gets its final touches before it heads into the open sea.
This complex process represents just a small glimpse into the extraordinary efforts behind shipbuilding. It’s not just about technology and machinery but also about ensuring that each detail, whether structural, aesthetic, or mechanical, is meticulously crafted. For Maersk, this transformation signifies more than the creation of new vessels; it’s about setting a course toward sustainability. The green methanol-powered ships are just the beginning of a new era in maritime transport.
