⚓🛠️ What Happens in a Dry Dock? Ship Maintenance Explained

My name is Davide Ramponi, I’m 21 years old and currently training as a shipping agent in Hamburg. On my blog, I take you with me on my journey into the exciting world of shipping. I share my knowledge, my experiences, and my progress on the way to becoming an expert in the field of Sale and Purchase – the trade with ships.

When we talk about shipping, we often focus on movement: voyages, cargo, and global trade. But even the most powerful ship needs to stop and be serviced. That’s where dry docking comes in—a technical, time-sensitive, and costly but absolutely essential phase in a vessel’s lifecycle.

Whether it’s routine maintenance, emergency repair, or a full-blown refit, dry dockings keep ships safe, compliant, and ready for the next journey.

🔍 In this post, I’ll walk you through:

✅ What dry docking is and why every ship needs it

✅ What tasks are performed while a vessel is out of the water

✅ How dockings are planned, scheduled, and budgeted

✅ What safety and environmental rules apply in shipyards

✅ What life is like for crew and project managers during a dry dock stay

Let’s step into the shipyard—and take a closer look at what really happens when a vessel goes dry.

🚢 What Is Dry Docking—and Why Does It Matter?

A dry dock is a specially constructed basin that can be flooded to allow a vessel in, then drained to expose the ship’s hull. This gives crews and contractors access to parts of the vessel that are normally underwater—so they can inspect, repair, clean, and upgrade the ship properly.

Why ships are dry docked:

• Regulatory compliance: Most vessels must be dry docked every 5 years to maintain class.

• Hull maintenance: Biofouling, corrosion, or damage to coatings must be addressed.

• Propeller and rudder checks: Only accessible when the ship is out of the water.

• Upgrades or retrofits: Ballast water systems, scrubbers, or structural changes require yard time.

🧠 Think of dry docking as a health check, cosmetic procedure, and performance boost—all in one.

🔧 What Actually Happens in a Dry Dock?

The moment the water drains, the work begins. Dry dockings follow a tight schedule—every hour counts, and downtime is expensive.

🧰 Common dry dock tasks:

1. Hull cleaning and repainting

   ➜ Removal of marine growth, followed by application of antifouling paint.

2. Propeller and rudder inspection

   ➜ Looking for cracks, misalignment, or wear and tear on the blades or shaft.

3. Steel repairs

   ➜ Corrosion in ballast tanks, hull dents, or cracks are repaired or reinforced.

4. Valve and sea chest maintenance

   ➜ All underwater openings are inspected, cleaned, or replaced as needed.

5. Cathodic protection renewal

   ➜ Sacrificial anodes are changed to maintain corrosion resistance.

6. Tank inspections and pressure testing

   ➜ Fuel, ballast, and water tanks are cleaned and tested for integrity.

7. Machinery overhaul (optional)

   ➜ Main engine, boilers, or auxiliary units may be overhauled during longer dockings.

🔍 For some vessels, class surveyors must also witness key stages like propeller removal or pressure tests—adding legal oversight to the technical process.

📅 Planning, Scheduling & Budgeting: No Room for Surprises

A successful dry docking doesn’t start when the ship enters the basin—it starts months in advance. Planning is essential to avoid costly delays or missing certification windows.

✅ How the planning process works:

• Pre-docking inspections

  ➜ Ship staff, superintendents, or external surveyors assess what needs doing.

• Specification writing

  ➜ Detailed job lists are compiled—including parts, coatings, and man-hours.

• Shipyard selection

  ➜ Chosen based on price, availability, facilities, and previous performance.

• Scheduling

  ➜ Dock slot booking is critical—especially during peak yard seasons (e.g., Q1–Q2).

• Cost control

  ➜ Every task is budgeted. Unexpected steelwork or scope increases can add tens of thousands of dollars per day.

💸 Typical dry docking costs for a medium-sized vessel:

• Docking services: $60,000–$150,000

• Paint/coatings: $50,000–$100,000

• Repairs: Highly variable

• Total: Often exceeds $500,000

🦺 Safety Protocols and Environmental Regulations in the Yard

Shipyards are busy industrial zones—working with cranes, welding equipment, high-pressure water jets, and heavy machinery. Safety and environmental responsibility are key.

🛡️ Safety Measures:

• Permit-to-work systems: Especially for hot work, tank entry, or working aloft.

• PPE and safety drills: Mandatory for all personnel, including visiting crew.

• Fire control and emergency access: Must be maintained during all operations.

• Confined space protocols: Gas-free certificates and rescue plans required.

🌍 Environmental Focus:

• Waste management: Paint chips, old anodes, and oily residues are hazardous and must be disposed of properly.

• Emission controls: Many yards now offer shore power or emissions capture during engine tests.

• Eco-friendly coatings: VOC limits and biocide regulations are becoming stricter globally.

In many cases, the shipowner is responsible for ensuring the environmental practices of the chosen yard comply with flag state or IMO standards.

🛏️ Life During Docking: Crew and Yard Culture

Dry docking isn’t just hard on the ship—it can be tough on the crew as well. Unlike at sea, where life is structured and movement is constant, yard stays are noisy, dusty, and sometimes chaotic.

What daily life looks like:

• Shore accommodation: Some crews stay in port hostels or guesthouses. Others sleep onboard—often with power outages or limited hot water.

• Mess schedule disruption: No galley access during certain works means catered meals or eating ashore.

• Crew duties: Officers often support inspections, sign off on worklists, or liaise with contractors. Engineers are especially busy.

• Cultural exchange: Shipyard workers, surveyors, flag inspectors, and crew all work side by side—often across language and cultural barriers.

🗣️ A Filipino third engineer once described dry docking as “a week of construction site chaos, mixed with pizza and pressure tests.”

🔍 Case Study: 7-Day Docking on a Feeder Ship

A real-world example from a recent container vessel dry docking in Turkey:

• Day 1: Arrival, deballasting, hull cleaning begins

• Day 2: Propeller pulled, rudder removed, anode inspection

• Day 3: Steel repairs in forward tanks

• Day 4–5: Repainting, internal coating touch-ups

• Day 6: Sea chest and valve replacement, safety gear checks

• Day 7: Refloating, main engine test, departure

💬 Total cost:

~$680,000📉

Delay:

1 extra day due to late steel delivery

📈 Result:

Class renewed, new antifouling system installed, crew happy with paint job

🧭 Conclusion: Dry Docking—Where Ships Hit Pause to Move Forward

Dry docking might take ships out of the water—but it’s what keeps them ready for the seas ahead. It’s a moment of pause, precision, and preparation.

Key Takeaways 🎯

✅ Dry docking ensures safety, performance, and class compliance for every vessel

✅ From hull cleaning to propeller repairs, dozens of tasks are squeezed into just days

✅ Costs and scheduling must be tightly managed to avoid overruns

✅ Environmental rules and worker safety protocols are critical at every stage

✅ Life during a dry dock can be hectic—but also full of learning and collaboration

👇 Have you ever been part of a dry dock project?

What was the biggest challenge—or most satisfying repair?

💬 Share your thoughts in the comments — I look forward to the exchange!

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