00:31 - Hi I'M RICK hammer assistant

00:32 - general manager here at Don Jon

00:34 - ship building in.

00:35 - Erie Pennsylvania.

00:37 - We've been around since 2009.

00:39 - We're a full service shipyard do

00:41 - everything from steel welding

00:43 - electrical jointer paint pipe if

00:46 - you want to join me take a tour.

00:51 - Okay.

00:51 - This is our engineering

00:52 - department.

00:54 - Typically what we do is we don't

00:56 - have a full in-house engineering

00:58 - department but we have a

01:00 - gentleman here that will support

01:03 - the production the different

01:04 - various vessels and projects

01:05 - that we work on.

01:07 - Typically we'd be getting a two

01:10 - dimensional CAD drawing on the

01:12 - table and what the gentlemen

01:14 - here do is they model the vessel

01:16 - and three dimensional

01:18 - space full size.

01:21 - What that does is this is a

01:23 - package we released to our guys

01:25 - allows us to put all the pieces

01:28 - together out on the shop floor

01:31 - each of them has a piece mark

01:33 - part number and dimensions and

01:35 - how to locate it.

01:37 - Each of these assemblies is

01:39 - constructed into modules and

01:41 - modules are put

01:42 - together in the dock.

01:45 - Also from this software we're

01:47 - able to take each individual

01:49 - piece that's modeled and lay

01:51 - it out onto the steel plate.

01:54 - The nesting allows us to utilize

01:57 - the maximum amount of plate

02:00 - possible the computer takes many

02:02 - iterations to place the parts to

02:05 - have the least amount of scrap

02:08 - of plate after this code to

02:10 - generate the NC codes generated

02:13 - and send it out to our plasma

02:16 - table out on the shop floor. So

02:20 - this is our NC plasma table.

02:24 - It's actually two tables water

02:27 - tables there 25 by 50 allows us

02:30 - to cut a 8 foot by 40 foot plate

02:34 - two of them on each table one

02:38 - table can be cutting and the

02:41 - other table is being loaded or

02:44 - unloaded it has two fully

02:47 - articulating beveling head able

02:52 - to cut up to 3 inch thick steel

02:56 - we also have oxy acetylene heads

03:00 - that are able to cut

03:02 - up to 6 inch steel.

03:04 - It also has the

03:05 - capability to etch the part to

03:07 - peace numbers in the orientation

03:09 - marks on each part labeled it

03:12 - so that the fabricators can

03:15 - assemble it. OK.

03:23 - Here you can see a piece of

03:24 - steel that's already been cut

03:25 - out.

03:27 - This is the power that nesting

03:29 - software where it can orientate

03:32 - these parts in the most

03:34 - efficient orientation possible

03:37 - to make the least

03:38 - amount of waste.

03:40 - Okay.

03:41 - Here you can see a panel that's

03:43 - already been etched in the

03:45 - corner over here you

03:47 - see the part number.

03:49 - It's our identifier hull.

03:51 - Twenty four twenty.

03:52 - Module seven piece two seventy.

03:56 - That coincides with the drawing

03:58 - so the assemblers putting it

03:59 - together know

04:00 - exactly which piece

04:01 - to put where. There's also

04:02 - an orientation icon in this

04:04 - corner shows you which direction

04:07 - is to the port and which

04:08 - direction faces forward.

04:10 - That just helps them locate the

04:12 - part in the assembly while

04:13 - they're putting it together.

04:15 - The lines you see running

04:16 - transversally and longitudinally

04:18 - on here are stiffener markings.

04:20 - What that allows them to do is

04:22 - place the stiffener on the mark

04:24 - and the tick mark shows which

04:27 - side the flange throws. This

04:30 - steps dramatically dramatically

04:32 - saves time on assembling the

04:34 - panels.

04:39 - This machine is a triple

04:40 - head seam welder.

04:41 - What it allows us to do is after

04:43 - the plates are cut on the NC

04:45 - table to the size we desire two

04:47 - plates are put together with the

04:50 - seam aligning on this copper

04:51 - bar running down the center.

04:54 - After that the triple head seam

04:57 - welder runs across the plate and

04:59 - makes one continuous full

05:02 - penetration Weld single pass

05:04 - from the top.

05:07 - Huge time saver reduces the man

05:09 - hours of manually welding the

05:11 - plate flipping it over gouging

05:13 - out welding the other side.

05:15 - This can all be accomplished in

05:17 - one process one step with this

05:18 - machine.

05:21 - This is our cassette for

05:23 - our stiffener Placer.

05:26 - What it allows us to do is pre

05:29 - layout which angles go on the

05:32 - panels.

05:33 - They can be placed in by the

05:35 - orientation that they show up on

05:37 - the panel.

05:38 - Those angles are then picked

05:40 - up by our stiffener Placer.

05:42 - There's a series of

05:43 - magnets at the bottom.

05:45 - After they get picked up they

05:47 - get placed on the panel.

05:49 - There's hydraulic rams that

05:50 - press the angled down in

05:52 - position and then lastly there

05:54 - is a welding trolley that runs

05:56 - across and tacks the

05:58 - angle into the position.

06:00 - This is a huge time saver as

06:02 - this would normally be a two man

06:04 - job and could take anywhere from

06:06 - 15 to 20 minutes to place a 40

06:09 - foot angle.

06:10 - It's rather heavy for two guys.

06:12 - This can all be accomplished in

06:14 - one step with one man operating

06:16 - this machine.

06:19 - Here you can see construction of

06:20 - a rudder for one of our newbuild

06:22 - projects.

06:23 - You can see it's just basic

06:25 - construction with the pipe on

06:26 - the leading edge and it's got

06:27 - baffles and diaphragms in here

06:29 - to stiffen it.

06:31 - There's a flange at the top that

06:32 - has the holes for bolting up to

06:34 - the rudder stock

06:35 - the vessel we're

06:36 - currently building we have

06:38 - three rudders so you can see

06:39 - there's three rudders in the

06:41 - process again built.

06:44 - And then after they're

06:45 - constructed they'll be painted

06:47 - and thrown on the boat.

06:50 - There we have a sub

06:51 - Mark seam welder.

06:52 - What this is a submerged arc.

06:55 - These two panels are tacked in

06:57 - place the very small gap in

06:58 - between and this machine runs

07:01 - along pours Weld down and

07:04 - completely bonding most plates.

07:06 - You can see the finished Weld

07:08 - over here looks pretty good

07:10 - machine quality Weld.

07:12 - After that this whole

07:14 - side is welded.

07:16 - This panel will be picked up

07:17 - flipped upside down and then the

07:19 - same thing will happen

07:22 - to the backside.

07:23 - OK now we're over here

07:26 - in the assembly building

07:27 - in this building.

07:29 - All the panels come through that

07:30 - were constructed in the fab

07:31 - shop.

07:33 - Each as all the angles fully

07:35 - welded ready to go they're cut

07:37 - to size and they're ready for

07:39 - assembly after these panels get

07:42 - delivered to the assembly shop.

07:45 - We'll put them up and the

07:47 - assembly fitters over here place

07:50 - the panels on our gym tables and

07:56 - the various modules. This shop

08:01 - has overhead capacity of 100 ton

08:04 - crane with two blocks and then

08:07 - we also have an

08:08 - overhead 20 ton crane.

08:11 - These are used for picking up

08:12 - the panels and holding them

08:14 - until they're tacked into place.

08:18 - Here you can see some deck

08:20 - houses typical construction is

08:22 - to build them upside down so the

08:24 - overheads are laid onto the jig

08:26 - table.

08:27 - The walls are stood up and then

08:29 - everything is welded a lot

08:32 - easier to weld down than it is

08:34 - to do weld overhead after it's

08:36 - assembled on the vessel.

08:40 - So here you can see the bough

08:41 - of one of our new construction

08:43 - tugs.

08:45 - In this stage we have to build a

08:47 - jig and it's actually orientated

08:49 - as it will be lowered into

08:51 - the dock and erect it.

08:54 - We also outfit it as much as

08:56 - possible with the bits chalks

08:58 - manholes.

09:00 - Anything that we can put on at

09:02 - this stage will be put on at

09:03 - this stage.

09:07 - So here's the mass.

09:08 - We have for our new

09:09 - build push tug.

09:10 - It's all aluminum completely

09:13 - welded and ready for

09:15 - installation on the vessel.

09:18 - So here we are we're inside the

09:20 - mid body module of our new push

09:22 - tug.

09:23 - As you can see we have

09:24 - some piping some pumps.

09:26 - The engines are in the gearboxes

09:28 - are in and obviously some paint

09:30 - has been started taking place

09:33 - electrical HVAC everything that

09:37 - we can get in at this stage up

09:39 - on the assembly for is a lot

09:41 - easier to install here than it

09:42 - is if we take it down into the

09:43 - dock and erect it

09:44 - to the next module.

09:47 - A lot of the equipment is large

09:48 - and the front end to this module

09:50 - is wide open.

09:51 - So now is the time to place

09:53 - the large equipment in.

09:54 - So we don't have the kind

09:55 - of hole to get it in later.

09:58 - Ok so here's a stern module

10:00 - of our new build push tug.

10:02 - You can see it's got the draft

10:04 - marks on it's got the fendering

10:06 - on it's got the bits the chalks

10:08 - the manholes it's ready to go in

10:10 - dock and be erected with the

10:12 - other modules after these all

10:14 - are erected.

10:15 - Be a much smaller version of a

10:18 - tugboat similar to this one

10:20 - right here.

10:21 - This is one of our repair

10:23 - jobs for the winter.

10:24 - It's a major Hull modification.

10:28 - It's going from a single rudder

10:31 - to two rudders the boughs being

10:34 - modified to fit the

10:36 - notch of a barge.

10:38 - And it's having a major

10:40 - accommodations overhaul as you

10:43 - can see we kind of have two tug

10:45 - boats in our dry dock right at

10:46 - this time.

10:48 - One's first a minor seal.

10:50 - Seal work and some steel repair.

10:53 - The other is a major

10:54 - modification changing a service.

11:00 - Typically we're flooding our dry

11:03 - dock with twenty three twenty

11:05 - four foot of water depending

11:07 - on how high the lake is.

11:09 - That allows the vessels to come

11:11 - in over the sill and we would

11:13 - have the docking blocks pre

11:16 - positioned with bobbers and

11:19 - other orientation aids.

11:21 - The vessel is then put over top

11:23 - of the blocks and then the water

11:25 - is pumped out.

11:27 - This dock is roughly able to

11:29 - hold 38 million gallons of

11:31 - water.

11:32 - We have two forty eight thousand

11:35 - gallon per minute pumps and to

11:38 - 7000 gallon per minute.

11:40 - Pumps that we use to de-water

11:42 - the dock takes about five and a

11:44 - half hours to pump

11:45 - all the water out.

11:47 - And at that point the boat would

11:50 - be sitting hard on the blocks

11:53 - and then we will be

11:54 - ready to get started.

11:56 - So here's our engraving dock

11:58 - just one of two of the largest

12:00 - ones on the Great Lakes.

12:02 - Total length twelve hundred and

12:04 - fifty feet with a total width of

12:06 - a hundred and thirty foot to get

12:08 - these vessels out of dry dock.

12:10 - What we would typically do is

12:12 - open the four large thirty six

12:15 - inch gate valves on the red case

12:17 - on what that does is allows the

12:20 - water to flood in fill up our

12:22 - dock equalizes with the water

12:25 - level of the bay.

12:26 - Once the water levels equalized

12:29 - we begin pumping out the case on

12:31 - which is the red gate there as

12:33 - that water is removed it begins

12:36 - to float floats out of its sill

12:38 - and then we can use winches to

12:40 - pull it to the side opening the

12:43 - end of the dry dock for the

12:45 - vessels to get in and out after

12:48 - the vessels in the dock.

12:50 - We would then pull the gate back

12:52 - in position and open a flood

12:55 - valve which lets water seep into

12:57 - the gate and sink it into place

13:00 - after the Gates fully sunk down

13:02 - and in the seal we then begin

13:04 - de-watering the grading dock

13:06 - only thing holding that gate in

13:08 - would be the pressure

13:10 - differential between the bay and

13:12 - the dock. So here

13:13 - you can see the

13:15 - back end of the barge at the

13:18 - mating tug is in dock right now.

13:20 - But you can certainly see how

13:22 - it has a gear running down the

13:24 - sides of the inside

13:25 - of the notch.

13:27 - That is to interconnect with the

13:29 - gear that is on the sides of the

13:32 - bow in the tug.

13:34 - That is what couples them

13:35 - together they operate as an

13:37 - articulated unit.

13:39 - Here you can see this is one of

13:40 - the top side vessels that we

13:42 - have in right now.

13:44 - Typically every year we would be

13:46 - doing steel repair any wasted

13:47 - steel would get removed and

13:49 - reinstalled with new steel.

13:52 - There's also some

13:53 - things that get

13:53 - damaged during the course of

13:55 - an operating season.

13:56 - Bent frames twisted angle those

13:58 - would be cropped out and renewed

14:00 - with new.

14:02 - Also just general maintenance on

14:03 - the conveyor belts and valves

14:05 - and machinery engine overhauls

14:08 - bough thruster seals all that

14:10 - stuff.

14:11 - Kind of the normal repairs that

14:13 - get postponed until the vessels

14:16 - lay up for the season and then

14:20 - we take care of it. Well this it

14:24 - for our tour.

14:26 - Hope you enjoyed yourself.

14:27 - Thanks for joining us.

14:28 - If you're looking for employment

14:29 - opportunities or some more

14:30 - information about our company

14:32 - please check out our website

14:35 - www.donjonshipbuilding.com

14:37 - Thank you.