From steel to sea: A shipbuilding from A to Z

Ever wondered how ships come to life? Long before the ceremonial champagne bottle shatters and a ship receives its official name, an incredible amount of planning and meticulous coordination unfolds. Take a behind-the-scenes look with Mikkel Jacobsen, Machinery Superintendent on Maersk’s site team in South Korea, and discover the intricate process that brings these giants of the sea into existence.

Maersk’s fleet is undergoing a significant transformation to support the company’s net-zero targets. So far, seven large newbuilds capable of sailing on green methanol have joined the fleet. While most people see the public naming ceremonies, for Mikkel Jacobsen, Machinery Superintendent, the story began long before that.

“It all started when I was asked to join the Maersk Site Team in Ulsan, South Korea, working with Hyundai Heavy Industries (HHI) to oversee the construction of these groundbreaking ships. It was a tough decision, but the opportunity was too unique to pass up. In March 2023, we packed up our lives – apartment, suitcases, and our three-year-old twin boys – and flew to the other side of the world. Throughout my decade at Maersk, I’ve seen the fleet from every angle, but this was something entirely new and transformative.”

Fast forward to the first vessel

A year later, after extensive training, endless machinery tests, and learning from some of the world’s best in their fields, Mikkel was given full responsibility for the machinery side on the Alexandra Mærsk.

The journey begins with the press of a button. In the massive production halls of Hyundai Heavy Industries, this button starts the cutting of the first steel plate. A gas flame slices through thick steel with laser-like precision, marking the official start of the ship’s construction in a process known as “steel cutting, Mikkel Jacobsen, Machinery Superintendent.

“This is where it all begins for the Maersk Site Team. Our job is to ensure Hyundai Heavy Industries (HHI) and Maersk stay aligned on safety, quality, and timelines. Once the steel is cut, it’s assembled into massive blocks – think of it like building with 'Lego.' These blocks are pieced together to form the entire ship. Our structural team, known as the Hull Team, oversees the steelwork, ensuring it meets the highest industry standards. Once the blocks are ready, the painting team takes over. From the iconic Maersk blue on the hull to the intricate internal tank coatings, they handle it all – using multiple tons of paint in the process!”

Meanwhile, the machinery and electrical teams rigorously test and inspect the equipment destined for the vessel. The next major milestone is 'Keel Laying' – the moment when the first block is carefully lowered into the dry dock. From that point, progress accelerates. Thousands of tons of steel are added daily, and the ship begins to take shape. The heart of the ship – the main engine – is installed, cables are laid, and the remaining steelwork is completed.

"Once external construction wraps up, the ship is ready for 'Launching.' Giant valves are opened, flooding the dry dock with thousands of liters of water every second. Over the course of several hours, the vessel gradually lifts from its supports. By the next morning, HHI’s powerful tugboats guide the ship out of the dry dock and over to the Outfitting Quay – where the real transformation happens.”