The famous green cranes, which are the symbol of Gdańsk, are working again. The powerful machines, which are one of the most characteristic elements of the city's panorama, will also be systematically modernized and renovated. All thanks to the Karstensen Poland shipyard, which purchased the area of the Gdańsk Shipyard and has already started building ships on it, and at the same time adapts it to its needs.

A large part of the land and facilities that were previously part of the Gdańsk Shipyard were sold to developers. Currently, modern office buildings can be seen from the side of Jana z Kolna Street, where the production halls were previously located. Therefore, the people of Gdańsk had concerns about the most characteristic shipyard area in their immediate vicinity – the one with seven green cranes, which for decades have been one of the most recognizable symbols of the city. The residents were afraid that sooner or later both the cranes and the hall with the iconic inscription "Stocznia Gdańska", visible from the street and from the SKM train stop, would disappear and new glass office buildings would be built in their place. Fortunately, nothing like that will happen. Ships are being built again in the most characteristic shipyard area. Kone green cranes are working again. All this thanks to the Karstensen Poland shipyard, which purchased the entire area in order to restore its basic function – production.

A shipyard remains a shipyard

For the last few years, Karstensen Poland has been producing modern fishing vessels at the production plant at the Indian Quay in Gdynia. However, the company felt the need for development. Last year, it managed to purchase a shipyard site with the infrastructure located on it in Gdańsk. This will open up completely new possibilities for Karstensen.

– I would like to emphasize and assure you that the Karstensen shipyard intends to build ships here. At the moment, three projects are already underway, at different stages. The first launch is expected at the beginning of September – says Bartłomiej Kopczewski, deputy director of Karstensen Shipyard Poland, when we are standing near the famous green Kone cranes and work is in progress around us. Ships are already being built, but infrastructure work is also underway.

– We have much bigger opportunities now. The area in Gdańsk is three times larger than in Gdynia. Besides, in Gdynia we are somehow limited by direct access to the waterfront. Here, however, we have the option of launching ships from two slipways, building several vesselst at once. Therefore, the production capacity is much greater – explains the deputy director of the shipyard.

Renovations are already underway. Green cranes will be like in the times of greatness

– At present, the production area is being adjusted to reach full production capacity – renovations, smaller investment works are underway – explains Kopczewski.

One of the most important elements of the infrastructure in this area are seven 150- and 50-tonne cranes. Thus, one of the investments that had to be planned and implemented in the first place was the replacement of the slewing bearing on one of the 150-ton colossi of the Kone brand.

– It's a very precise job – says Paweł Maśliński, transport manager at Karstensen Poland. – It consists in supporting the entire upper part of the crane with three pumps, extending the slewing bearing, attaching it to the second crane and pulling it down, and installing a new bearing in its place. The preparations took about two months – it was loosening the screws, static tests, measurements, blocking the cranes, waiting for the right weather... – he says.

The team of fitters who worked at height disassembling the old and installing the new bearing consisted of about 10 people. Throughout the operation, a huge crane hung above their heads, supported by only three pumps, and only on one side, to allow the bearing to be removed.

However, the planning of the operation started much earlier, about six months ago. During this time, Karstensen's team had to deal with a lot of technical issues, measurements, orders and even problems with special pins that the German factory supplied in the wrong size. Everything required time and appropriate financial outlays.

– About ten days after everything is assembled, the crane will undergo technical supervision tests and return to its glory days. It should serve us for the next 30 years – says Paweł Maśliński. However, he assures that this is not the end of the work on the famous shipyard cranes. – We have a repair, maintenance and modernization schedule for the cranes for the next 5-6 years. Later this year, we should carry out another bearing replacement on the 50-tonne crane, which is on the same subgrade. In the following years, three more cranes await us. In the meantime, we will wash them so that they return to their original color, we will have maintenance work, repair of the barriers, working platforms. There's a lot of it. We have to find a compromise between maintaining the continuity of production and these services – explains the transport manager at the Karstensen shipyard.

A modern establishment with respect for history

It's not just cranes that need attention. The whole area must be adapted to the needs of a modern production plant. Some infrastructural facilities that have not been renovated and maintained for years need modernization. Renovation work is already underway on the premises for employees and offices. As Kopczewski says, the shipyard wants social conditions to be at the highest possible level. They are currently used by over 200 people who are already building ships here.

– Ultimately, the entire production will be transferred from Gdynia to Gdańsk in the middle of the year. Ultimately, about 700 people representing various specialties will work here – says Bartłomiej Kopczewski, deputy director of the shipyard.

Karstensen Poland is already planning other key investments.

– In the future, we want to build a partial roof for the B1 slipway. As a result, we will improve working conditions when equipping ships, and at the same time we will limit the impact of shipyard work on the surrounding environment. Secondly, we plan to build a facility for prefabrication and prefabrication, i.e. sheet metal burning, forming and bending, and prefabrication, where robotic processes will also take place – explains Kopczewski.

Thanks to this, the technological line at the Karstensen Poland plant in Gdańsk will be simple – ship sections and blocks will be built in the hall and on prefabrication yards. Then they will be transported by self-propelled platforms to the vicinity of the cranes. There they will be finished and assembled, and then launched.

The shipyard area purchased by Karstensen Poland is under the supervision of the conservator of monuments. However, this is not an obstacle for the company, because its goal is to restore the facilities to their basic production function with respect for the legend and history of this place.

– We would like all residents of Gdańsk to know that this area is alive, that it is a production area, as it was in the past. We know that the Gdańsk community keeps their fingers crossed for us and encourages us to keep this strictly production area working, building ships and being, in a way, a showcase of this part of Gdańsk – assures the deputy director of the shipyard. – We work closely with the provincial conservator of monuments. As this is a protected area, we have to agree on many things together. We want to fully preserve, restore and restore the historical elements, he explains.

In this way, not only large elements of infrastructure will be preserved, such as the aforementioned cranes, which are still awaiting e.g. derusting, but also all historical information and health and safety plates standing on the premises of the plant. They will be repainted.

Another important historical element is located on the façade of the production hall. It can be seen from a distance – from the street and the stop of the Fast Urban Railway.

– The inscription "Stocznia Gdańska" remains – Bartłomiej Kopczewski says briefly.