2) United States Patent
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4470850
4985308
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AR FLOATING DRY DOCK
1e Kenneth Dye,
Seappoose, OR
w
‘Wayne Kenneth Dye, Scappoose, OR
ws)
Subject to any diselaimer, the term of this
pateat is extended or adjusted under 3
USC. 154(b) by O days
Appl. No. 14/639,094
Mar. 4, 2015
(2006.01)
(2005.01)
(2006.01)
B63C 1/02 (2013.01), BOB 3/08 (2013.01);
‘BSB 99065 (2013.01)
sation Search
BOSC 1102; BOSB 308
1445-46, 263
search history.
Chas
References Cited
US. PATENT DOCUMENTS
A * 101984 Landre ore 04
note 02
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US 9,266,590 BI
Feb. 23, 2016
(10) Patent No.
4s) Date of Patent:
SAULTOE A * $1992 D'EHoere bos 35.003
114259
513896) 4 + 81992 Fichert Baan Sas
520.246 4 * 121993 Golbach 638 320
118.263
700,916 BL* 42009 Nelson akc 102
7.603.959 BL* 102009 Vearey boss 808
114263
200710283866 AL* 12/2007 Veazey Ao1K 61,08
* cited by examiner
Lars A Olson
fovon Hayes
Kolisch Harwell, PC
Primary Examiner
Assistant Examiner
(74) Auornes, Agent, oF Firm
on ABSTRACT
An enclosable, modular floating dry dock
plurality of loodable flotation modules coupled to a eet
Support member at spaced intervals, such that gap
Formed between successive flotation modules. Each ap may’
be spanned by a deck and/or wall. working volume may be
defined erween an interior of the Moating dry dock and a
supported watercraft. The working volume may he environ-
mentally enclosed by drapes coupled tothe dry dock.
ay include
1
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oeUS 9,266,590 BI
1
MODULAR FLOATING DRY DOCK
FIELD
‘This disclosure relates to systems and methods for placing
‘a watercraft into dry dock snd supporting it thee, More
specifically, the disclosed embodiments relate to enclosed,
modular floating dry docks,
INTRODUCTION
Watercraft of al shapes and sizes require maintenance and
repairs from time to ime, These activities sometimes require
the vessel to be removed from the water. For example, work
‘onthe exterior hull of a boat (e3., painting) may be impos
sible or dificult when the hull sin the water. In ome cases,
repairs or upgrades toa watereraft quires breaching the hull.
‘Thisis impractical andinadvisable if the watereaft is looting
in the water. Accordingly, various methods for conducting
such work have been devised over the centuries. Smaller
vessels may be lifted out a the water by rane or davit, and
work may be conducted either on land or onboard a larger
vessel Langer watercafl, sich as ships and oceangoing boats,
‘ay be removed from the water using a dry dock. Dry docks
{all ato two main categories: loating and non-fleaing, Non-
floating dry docks are essentially basins formed ether on
shore or attached to shoreline, A vessel may be floated into
the basin, and thea the basin is drained, leaving the ship on @
‘dy platform, In other words, the basin of @nonefloating dry
‘dock is a stationary receptacle capable of being emptied by
Pumping water out
‘A floating dry dock, on the other hand, is designed to be
parially sunk. A floating dry dock typical has a U-shaped
‘ross section and Mloodable flotation ebambers. When the
‘deck ofthe foating dry dock is submerged, a watereraht may
be positioned over the deck by simply drivingt into position.
The dry dock is then raised tinder the vessel by pumping oF
ctherwise forcing water out of the flotation chambers. Water
above the deck exits via the open ends of the U-shaped siue-
ture, uatil both the deck and the vessel are above the water=
line, Oneadvantaze floating dry dacks have isthe ability tobe
peographically located
However, floating dry docks for ships are typically quite
large, and donot aecommodute medium sized boats in the 60-
to S0-ton range. Standard Hoating dry docks may be resized
by hooking dry dock sections together, However, combining
lange dry docks into larger dry docks isnot a feasible solution
or boat and yacht owners who desire a customized dry dock
Jor their watereraft. Additionally, because of their open-ait
design, standard floating dry docks have environmental
impact issues. Debris, panculate, and both liguid and air-
bbome contamination are frequently released into the sur-
rounding waters
SUMMARY,
‘The present disclosure provides systems, apparatuses, and
methods relating to modular Hoating dry docks. In some
abodiments, a Mating dry dock may inelude a pair of side~
by-side elongate members defining a central axis. plurality
‘of Used lotation modules may be disposed ina spaced
relationship along the central axis, ech flotation module
‘including a teansverse tank, frst upright tank disposed at 9
first end of the transverse tank and a second upright tank
ssposed at a ssoond end of the transverse tank, each trans
verse tank-being coupledto the pair of elongate members sich
that a respective gap is formed between each pair of adjacent
0
o
2
‘oration modules. Fach gap may include first void between
adjacent transverse tanks, the fist void being spanned by &
eck, and a second void between adjacent upright tanks, the
second void being spanned by a wall
Tn some embodiments a floating dry dock system may
‘include a floating dry dock incluing a pair of wing walls, a
deck conneeting ower end portions ofthe pair of wing walls,
‘and plurality of ftaton tanks integrated with the dock and
‘wing walls at spaced interals along a length of the Boating
dy dock. One or more lexble sheets may be coupled to the
dy dack. A watercraft may be supported by the Hosting dry
dock between the wing walls. A working volume may be
define between an ouler surface of the Watercraft andl aa
‘nner surface ofthe dry dock, The working volume may be
enclosed by the one or more flexible sheets
Ta some embodiments, method of manufacturing a float-
ing dry dock may include placing a plurality of substantially
identical elongate tanks into a body of water. Bach of the
elongate tanks may be coupled to a keel support assembly
having atleast one elongate support member defining long
axis, suc thatthe elongate aks are spaced along the elt
{gle support member and oriented transverse tothe long ay
orming a respective gap between each adjacent pair of the
clongate tanks. A plurality of U-shaped flotation modules
‘may be formed by attaching an upright tank to each end
portion of each of the clongete tanks, The gap between each
‘adjacent pur of elongate tanks may be covered with one oF
‘more decking materials
Features, functions, and advantages may be achieved inde
pendently in various embodiments af the present disclosure,
‘ormay be combined in yet other embodiments, further details
‘of which ean be seen with reference to the following desrip-
‘ion and drawings
[BRIEF DESCRIPTION OF THE DRAWINGS.
FIG. 1 isa schematic diagram depicting an end elevation
view of an illustrative Hating dry dock supporting a water
eral
FIG, 2 an overhead plan view of an iustrative floating
‘dry dock in aevordance with aspects othe present disclosure
FIG. 3s a side clevation view of the Noating dry dock of
FIG.3.
FIG. 4s an end elevation view ofthe Noating dry dock of
IG. 3 with an illustrative watercraft supported thercon
FIG. $ is an isometric exploded schematic view of an
illstative Boating dry dockin accordance withaspects ofthe
present disclosure
FIG. 6s a flow chat of steps performed in an illustrative
method for manufacturing a Mating dry dock in aevordance
‘with aspects ofthe present disclosure
FIG, 7 isa flow char of steps performed in an illustrative
smthod for using a floating dry dock in accondance with
aspects ofthe present disclosure
DESCRIPTION
Overview:
‘Various embodiments of a modular loating dry dock hav
‘ng improved environmental impact prevention are desribed
‘elon and illustrated inthe associat drawings. Unless oth-
evs specified, a floating dry dock andor its Various com-
ponents may, but arenotequiredio,containat least neo the
Structure, componenls, Tinetionality, and/or variations
eseribed, illustrated, and/or incorporated herein. Further-
nore, the process steps, structures, components, funetional-US 9,266,590 BI
3
ites, andor variations described, ilustrated, and/or incorpo-
ruled herein in connection wth the present teachings may. but
‘re not required to, beineluded in other similar dry docks. The
Tollowing deseription of various embodiments is. merely
‘exemplary in nature and is in no way intended to Timit the
disclosure, its application, or uses. Additionally the advan-
tages provided by the embodiments, as desribed below, are
istrative in nature and aot all embodiments provide the
same advantages of the same degree of advantages
In general, 2 modular floating dry dock may include &
selected plurality of Usshaped composite tank strctures
‘ranged at spaced intervals and connected by bracing met-
bers, contra beams, and walkways, The mmber of tank
Structures, also refered to herein ss pontoons, may’ be
selected! based onthe size of watercraft w be accommodate.
Furthermore, a modular eating dry dock may inelude fea-
tures peoviding significantly redtuced environmental impact.
Forexample, dry docks ae typically wsedto support a water
‘raf for maintenance and repair activities that produce lig,
‘old, andlor airborne contaminants, A floating dry dock ia
socordance with aspects of the presen disclosure may
include one or more enclosure andor containment features
that prevent or greatly redice the release of stich contami
nants tothe surrounding environment
Turning to FIG. 1, a schematic diagram of a modular,
‘enclose, floating dry dock system 10 is depicted. Dry dock.
system 10 may include a floating dry dock 12, one or more
‘enclosure drapes 14, nd ventilation system 16, Floating dry
‘dock 12 may include a pairof wing walls 18,20 connected by.
‘a deck 22. The dry dock may be supported by a plurality of
Usshaped flotation modules 24 (also refered to as tanks oF
tank assemblies) coupled to deck 22 and/or wing walls 18,20
Insome examples, flotation modules 24 forma portion ofthe
deck andor wing walls
The size and iting capacity of floating dry dock 12 may be
‘determined at least in par by the selected numberof tation
modules 24, For example, five flotation modules may be
selected 1 support a watercraft 26 of a certain size and
‘ight, In other embodiments, watercraft 26 may be smaller
‘and lighter, and four flotation modules may be utilized
Accordingly, Hating dry dack system 10 may be sealable or
variable withina range of sizes. In some embodiments, loat-
ing dry dock 12 may be configured to mse and support an
‘expected size and type of watererall (ea 80-t0n bot).
ach Notation module 24 may includeone or more aks 28
(olso referred wo as tank portions), For example, 28 shown ia
FIG. 1, flotation module 24 may include a transverse tank
28, a firs upright tank 28B, anda second upright tank 28C.
The upright tanks may be coupled or affixed to an upper
surface of the transverse tank, as shown in FIG. 1. In ethee
‘embodiments, the transverse tanks may be affixed tothe ends
‘of the transverse tank. In some embodiments, tation mod=
tule 24 may comprise a single tank,
"Apairofwallovays 30,32 may bedisposed atop wing walls
18,20, such that walkway 30 spans the upper ends of upright
tanks 289 and walkway 32 spans the upper ends of upright
tanks 28C. Walkways 30 and 32 may include any suitable
structure configured te provide a walking surface for persons,
‘and may include mooring features for securing watercraft 26,
(ex, bits, bollads, andlor the like). The walkways: may
inchide other suitable featutes, such as banda
‘Watereraft 26 may inchude any’ suitable waterbome vessel
‘or eaf,sueh asa boat, ship, or the lke, Floating dry dock.
12 may inclade a kes! support 34. Keel support 34 may
‘include any suitable strate configured o contact a ker
portion of watercraft 26 and support the weight ofthe water
‘raft when raised out ofthe water, For example, keel support
0
o
4
34 may include a plurality of transverse beams or blocks
‘isposed along a central long axis ofthe dry dock. One oF
‘more beams or other support members may run along the
central long axis to provide additional support and connee-
tivity between Notation modules,
Raising (ie, floating) and lowering (sinking) of flo
‘ng dry dock 12 may be facilitated by a pneumatic system 36
configured to vent or pressurize Hotation modules 24. Pace
‘matic system 36 may be manipulated using contol valves,
represented hereby a valve 38. A plurality of such valves oF
valve controllers may be arranged ata control panel 40 for
‘operation a a single locaton, Fach valve 38 may’ include one
‘oF more pneumatic valves. Tn some embextiments, valve 38
may inelude a three-way valve and/or a buitefly shutofT
valve. To pressurize thelotation modules, oraportionthereot
(ea transverse tank portion), air may be blown or pumped
into the tank by a blower 42 through valve 38 and pneumatic
system 36. Blower 42 may include any suitable ar compres-
soror blower.
"Tossa in sing Watercraft 26, the weight of floating dry
dock 12 strictures may be partially or completely offset by
supplemeatal oats 44. Floats 44 may include any suitable
faturaly buoyant structure configured to contribute by
fancy tothe dry dock when attached thereto, and to partially
offset the weightof the dry dock stractue. For example oats
“44 may include one or more closed-cell foam blocks. Fos
blocks (e., Styrofoam blocks) may be encased in plastic
(ea, by shrink-wrapping) for waterproofing and structural
integrity Floats 44 may be disposed in any suitable location
fn the dry dock. In some embodiments, floats 44 may’ be
placed between Rotation modules. In same embodiments,
oats 44 may he placed under the kel support are, as indi
cated in FIG. 1.
To facilitate environmental containment of debris and par-
siculates, gaps between flotation modules 24 may be filled by
decking and walls (a0t shown in FIG. 1). Additionally, apes
14 (also rofered 1 as sheets) may’be placed over the othor-
wise open ends of the dry dock (3t 14) and over openings
between watercraft 26 ancl wing walls 18 and 20 (at 143 and
14€), Sheets or drapes 14 may include any suitable flexible
structure configure to be geterally impermeable to liquids
(eg, water) and gasses (eg air). For example, drapes 14
‘may include one or more plastic or vinyl tarps. In some
‘embodiments, portions of drapes 14 may be affixed to oating
‘dy dock 12. la some embodiments, drapes 14 may be selec-
tively attached to portions of dry dock 12 by fasteners and
Tiastening systems included for that purpose. In some
examples, drapes 14 may pass completely overthe watereraft,
enclosing the watercraft in the dry dock. In some examples
rapes 14 may pass from an outer perimeter of the watereraft
to the dry dock, thereby enclosing a space 46 between the
call andthe interior of he dey dock. Space 46 includes the
area where work is typically performed by persons and
‘machinery in the dry dock, such as on the hull of watereraft
26, Accordingly, the enclosed space 46 may be referred tas
the working volume,
“The walls, decks, Notation modules, and sheets of system
10 function to contain debris and particulate matter, as Well as
airbome contamination, Liquids used or produced within the
enclosed dry dock may be retained in any suitable structure,
suel as one or more sumps 48, These liquids, whieh may
contain contaminants, maybe storedor hold until pumped aut
of the dey dock to suitable containers or processing s¥stems,
Airborne particulates and contaminants may be handled by
ventilation system 16. Ventilation system 16 may include a
‘entiation fan SO anda serubher $2. Air from enclosed vol-
‘ume 46 may be exhausted through the fan and serubber.US 9,266,590 BI
5
some embodiments, make-up or supply air may be provided
by a supply’ fan. In some embodiments, make-up air may be
piled into the enclosed volume through the ation of fin 80.
A slight pressure diferential may be maintained, such that the
pressure inside enclosed space 46 may be slightly lower
than atmospheric pressure outside the space. This rrange-
‘met helps prevent undesired escape of arbome contamin-
tion from the enclosed space.
Examples, Components, and Altematives
‘The Following sections deseribe selected aspects of exem-
plary modular floating dey docks as wel as related systems
‘and/or methods. The examples in these sections are intended
{og illustration and should not be interpreted as limiting the
tre scope of the present disclosure. Fach section may
‘include one or more distinct inventions, andor contextual of
related information, function, andor structure
Section |
‘As shown in FIGS. 2-5, this setion describes an enelos-
able, modular, floating dry dock 100. Dry dock 100 is an
‘example of dry dock 10, described above. Accordingly, simi
lar components may he labeled with similar reference aum-
bers
FIG. 2s an overhead view of ry dock 100, showing the
serangement of flotation modules and decking material, as
wells keel support assembly. FIG. 3 isa side elevation view
‘of dry dock 100, showing the location modules, wall eover-
‘ings, braces, and placement of supplemental buoyaney and
stability components. FIG. 4 is an end elevation view, shox
ing structures of a fotation module, as well as including 2
waterraft and various drape-related elements. FIG. $is un
‘exploded schematic view showing relationships between
‘various components of dry dock 10.
Floating dry dock 100 inclides a series of substantially
‘entcal flotation modules 102 couple! to a keel support
sembly’ 104 Inthe embodiment shown in PIGS. 2-5, fot
ing dey dock 100 inclndes five flotation modules, 102A,
1028, 102C, 102D, and 102E. However, any suitable sumber
‘of flotation modules 102 may be selected. For example, more
fo fewer flotation modules may be selected, based on the
Jength andor displacement ofthe watercraft tobe supported.
Fach lotation module 102 may include any suitable strc
‘ureand/orapparatus configuredto providea selected amount
‘of loodable buoyancy. Insome embodiments, flotation mod-
tle 192 may inciude submodules, partitions, or ank portions.
For example, each ofthe flotation modules depicted in FIGS.
2-5 may comprisea U-shaped sircture inelding transverse
tank 106A-106E 0 first upright tank 1O8A-108E, anda sec-
‘ond upright tank 110A-110E. Primary buoyancy may be pro-
vided by the transverse tanks. "Te upright tanks may provide
primary and reserve buoyancy, 36 well as stability when the
transverse tks are submerged.
‘Fach transverse tank may include an elongate rectangl
tank oriented athwart Keel support assembly 104. Although
rectangular tanks are deseribet and depicted inthe drawings,
‘any given tank may be any suitable shape. Por example, 3
transverse tank may be cylindtical or polygonal. Transverse
tanks 106A-106E: may comprise any suitable Notation tank
‘material configured o provide structural and weight-bearing
suppor for the overall dry dock system. Forexample, a rans-
verse tank may comprise ste, stainless steol, composite
‘material, or the like, or a combination thereat.
‘Keel suppor assembly 14 defines a central lng axis X of
‘dry dock 100 (see FIG. 2). The transverse tanks may be
described as being oriented transverse or laterally perpen=
‘cular to longaxis X.In some embodiments, sc 2s the one
0
o
6
shown in FIGS. 2.8, each transverse tank 1064-1065, and
therefore each flotation module 102A-102E may be centered
‘on Tong axis X, In some embodiments, each transverse tank
‘may comprisea rectangulartank, 36-fest lng (ina dimension
perpendiculartothe Xaxis)by four feet tall (i.e high), by six
{eet wide (ie, ina dimension parallel tothe X axis)
The transverse tanks, being Hoodable, will from time to
time he partially fooded. To reduce the instability caused by
the free surface effect in an elongate tank, each of the trans:
verse tanks may include one or more internal bulkheads and!
orbalfles. For example, refering to flotation module 102, in
FIG. 8, each transverse tank may include a central bulkhead
112, Being coupled to kee! support assembly 104, the trans-
verse tanks willalso bear the wejhtof the waterraf. Various
features may be included to facilitate this weight-bearing
‘unctionality. Reinforcing frames, also refered to ss braces
andlor ribs 114 may be attached to inner andlor outer walls of
transverse tanks 106A-106E to distribute the weight of the
watereraft and related forees along the length of the tanks,
thereby preventing concentration at a center portion, For
‘example, ribs I14 may include angle ion segments welded to
fone oF more walle of the tks. Similar features may be
Jnclded in other tanks or tank portions
Upright tanks 1084-108E and 110A-110E may include
‘any suitable structe configured to provide buoyaney and
‘ability wo loating dry dock 100, Upright tanks 108A-1081:
‘may be flodable, and may partially submenge during oper-
‘ion of the dock, In some embodiments, each upright tank
‘may be approximately eight fect tall, with @ fourtoot by
sixoot rectangular base, Upright tanks 108A-108E may be
interchangeably refered to as wing tanks. As mentioned
hove, each pair of side wing tanks may be disposed in a
eshapedl armingement with transverse tank at ther base, la
some embodiments, as depicted in FIGS. 28, upright tanks
108A-108E and T10A-110E may be connected to respective
‘upper surfiees of transverse tanks 106A-106E, In some
cmbodimients, the upright tanks may be connected to end
strfaces of the transverse tanks. Any suitable connection
geometry may be used. For each flotation module 102, two
upright tanks may be fastened to the transverse tank. For
‘example, the wpright tanks may becotnected tothe transverse
tank by welding, fusing, adhering, riveting, bolting, strap-
ping. oF the like, orany combination threo
‘Keel support assembly 104 may include any suitablesteuc-
ture configured to provide a central spine for coupling With
the flotation modules and to supporthe weight ofan expected
\watererft, Tor example, Keel support assembly 104 may
include a pair of side-by-side elongate members 116, 118
running parallel to central axis X. In some embodiments, a
single elongate member may be present. Elongate members
116,118 may include any suitable beam or structural clement
For example, elongate members 116, 118 may comprise
[Lheams. For example, iwelve-inch steel Lheams may be
ved. Fach elongate member may inchade one or more
beams. For example each elongate member may include a
plurality of similar Hheams weldedend to endto formasingle
[Pbeam running the length ofthe dry dock,
‘Keel support assembly 104 may include a plurality of keel
blocks 120 arranged at spaced intervals along the length of
elongate members 116 and 118. Kel blocks 120 may be
‘oriented teansverse to central axis X to better support a keel
122 of a watereaft 124. Keel blocks 120 may include any
stable struture configured to collectively support Keel 120
of wateroraft 124. Keel blocks 120 may include blocks,
‘beams, pedestals, or the ike or any combination of these. In
the embodiment shown in FIGS. 2-5 kel blocks 120 include
[beams that lie across and ae attached to elongate membersUS 9,266,590 BI
1
116 and 118, For example, keel blocks 120 may include
sixcinch | beams, ech approximately four fot long and tack
‘welded to he I-beams of members 116 and 118, Keel blocks
120 may be sized and shaped to withstand a predetermined
amount of supported weight, Fach ofthe keel blocks 120may
be configured with a breaking pont, at which point an indic
Vidal Kel block is designed to fil For example, each keel
block 120 may be configured o fail at appronimately twenty
tons. This feature enhances the safety of ating dey dock 100
by ensuring that any single point of excess pressure on keel
support assembly 104 will be distbuted along the elongate
members. For example, ifun object were to be stuck to kee]
122, and the object came into contact with kool support
assembly 104, the point of contact would experience a pro-
portionally eater load than expected. Rather than possibly
bending elongate members 116 and/or 118, contact with 3
single keel block 120 will simply cause the individual keel
block to fail, allowing the rest of the keel to rest on the
remaining kool blocks and distributing the load,
‘Keel suppor: assembly 104 is supported by and coupled to
the transverse tanks of flotation mextules 102. Accordingly,
‘each transverse tank 106 may include a mounting interface
126 configured to facilitate coupling. For example, mounting
Interface 126 may include one oF more channels 128 (also
referred o a8 ocesses of tracks) running parallel to central
‘axis X across the axial Widibof each transverse ank. Blongate
members 116, 118 may be at least parilly disposed and
scoured in channel(s) 128, For example, elongate members
(6 and 118, in the form of I-boams, may be welded,