Zvezda Shipbuilding Complex is being built as part of an expansion to the existing Zvezda shipyard owned by United Shipbuilding Corporation. The complex is located in the town of Bolshoi Kamen in the far-east of Russia.

The total cost to construct the shipbuilding complex is estimated to be RUB150bn (approximately $4.2bn). Upon completion, the Zvezda Shipbuilding Complex will be the biggest shipbuilding complex in Russia, fitted to build all types of naval and merchant ships.

The Far Eastern Shipbuilding and Ship Repair Center (FESRC) is developing the shipbuilding complex in Russia’s far-east as part of the development works to organise domestic shipbuilding in the north-west, far-east and south.

The Damen Song Cam Shipyard (DSCS) is located in Haiphong City, Thuy Nguyen district in Vietnam.

Russian energy companies Rosneft and Gazprombank signed a Memorandum of Understanding (MOU) with Korean shipbuilding company Daewoo Shipbuilding & Marine Engineering and Russia’s largest shipbuilder Sovcomflot to construct a shipbuilding and industrial cluster in the southern part of Primorskiy Krai. The conglomerate jointly agreed to develop a Russian-Korean engineering centre in 2016 for shipbuilding and marine equipment for offshore projects.

Capacity expansion works of the yard are being executed without interrupting operations of the existing yard. Construction works started in 2012 and are expected to be completed by 2019.

The project, designed by JSC Shipbuilding and Ship Repair Technology Center, will provide employment to approximately 9,700 people.

Construction of the complex

The Zvezda Shipbuilding Complex facilities are planned to be developed in four phases. The first phase includes the installation of a hull fabrication workshop and painting workshops. The second stage will consist of building the open land-based construction area and associated workshops. Dry docks and outfitting workshops will be built in the third phase, while the fourth phase will include development of the land-based construction area for the offshore structures at the complex.

Construction works on the first phase began in 2012 and are expected to be completed by 2014.

On completion of the construction activities, the shipbuilding complex will be able to build tankers with a displacement of up to 350,000t, as well as LNG carriers, ice breaking vessels and other specialised vessels and structures.

Shipbuilding facilities at the shipyard

Zvezda Shipbuilding Complex aims to increase the production capacity of the existing shipyard. It will build navy and commercial vessels, offshore construction vessels and ice class vessels for use in the Arctic region. The shipyard will also be fitted with equipment for the construction of offshore platforms and other marine structures.

“The workshop will process 45,000t of steel annually from 2015 and the capacity will be doubled to 90,000t from 2018 onwards.”

The 55,890m² hull fabrication workshop will consist of six large bays equipped with machines and automatic lines. It will be 315m-long, 192m-wide and 36m-high. An open outfitting platform 485m-long and 230m-wide will also be constructed as part of the first phase.

A profile cutting machine, a plate cutting gantry, production lines to be installed for micro panels and equipment required for curved unit fabrication are included in the first bay.

The largest piece of equipment, a line to produce flat units costing approximately RUB3bn ($84.12m), will be installed in the fifth bay. It will be Russia’s biggest automated line weighing approximately 350t and will assemble flat units measuring up to 20m in length.

The workshop will process 45,000t of steel annually from 2015 and the capacity will be doubled to 90,000t from 2018 onwards.

Contractors and suppliers

Installation works in the first phase are being directed by IMG specialists. General contractors RDS Companies was responsible for hoisting the 42t crane runway beam into the hull fabrication workshop structure.

Finnish company Konecranes will supply 15 tailor-made cranes with automatic mode, each capable of hoisting 120t, to the shipbuilding complex. The cranes will primarily be CXT and SMARTON cranes.