At the Szczecin Shipyard “Wulkan”, an operation is currently underway the likes of which the Polish coast has not seen for years. The construction of the colossal Dock No. 8 for Szczecin-based “Gryfia” is an engineering masterpiece involving Norwegian pontoons and Belgian transporters. The completion of this project could take customers away from the biggest players in the Baltic.
This is the first operation of this scale and type in Poland
On Sunday, 19 April, the central section of the new floating dock, weighing 3,600 tonnes, was moored at the quay of the Szczecin Shipyard “Wulkan”. In the coming days, the second 80-metre module will be launched, after which the process of assembling the structure will begin. The project is due to be completed in July 2027. Once commissioned, it will be the largest floating dock in the Baltic Sea.
The central hull module of the dock for the Gryfia Repair Shipyard is already on the Oder. The operation to launch the 3,600-tonne structure, with its impressive dimensions (70 m long, 46 m wide), required sophisticated logistics. A huge pontoon imported from Norway, Belgian SPMT self-propelled transporters and a fleet of tugs were used for this purpose.
This is the first operation of this scale and type in Poland. The entire hull will be assembled on the water. All the equipment was transported to Szczecin by several dozen lorries, says Grzegorz Huszcz, representative of the management board of the Szczecin Shipyard “Wulkan” for production organisation
The entire operation, from moving the structure onto the pontoon to mooring it safely, took around eight hours. The challenges were not only the dimensions of the dock but also the weather conditions. Due to its surface area, the structure behaves like a giant sail, meaning that even a light breeze generates enormous forces on the quay and mooring lines.
The next stage of work is scheduled for the coming days: the launching of the second module, over 80 metres long. It currently rests on the “Odrza Nowa”, a former slipway that has been converted into an assembly yard. Towering over this massive structure is the distinctive gantry crane bearing the inscription “Stocznia Szczecińska”, one of the city’s most recognisable symbols, welcoming those entering Szczecin.
Will the construction of the dock cost a total of around PLN 400 million?
The 240-metre floating dock is being built at the “Wulkan” shipyard on behalf of neighbouring “Gryfia”. Since the contract was signed in 2020, the investment costs have risen dramatically: from an initial PLN 130 million, through estimates of PLN 160–180 million, to over PLN 250 million in 2024. Despite such substantial expenditure, the progress of the work was estimated at the time to be a mere 30–35%. In the face of these difficulties, it became necessary to optimise and ‘streamline’ the original project.
Information provided by, among others, experts from the shipbuilding industry suggests that the construction of the dock will cost a total of around PLN 400 million (over 94 mln euro).
“Immediately after the launch of the second module, we will begin assembling the third module, for which we have 100 per cent of the sections prepared and painted,” says Grzegorz Huszcz.
As Huszcz points out, the entire construction process takes place on the premises of the Szczecin Shipyard, utilising its full infrastructure: from halls and processing lines to assembly yards and quays. Although the Szczecin Shipyard is responsible for organising the project, its implementation relies on close cooperation with specialised companies operating on its premises.
Photo credit: WULKAN Shipyard
The launch of the second module is the next step in the project
On 22 April this year, the launch of the second module was completed. The video below shows the entire operation: from the transport of the structure to its safe placement in the water. This is a good opportunity to see the scale and precision of the work carried out at the Szczecin shipyard.
Completion of the project in July 2027
The next stage of work, the launching of the third module, is scheduled for a few months’ time. The final assembly of all three sections will take place directly on the water, as well as beneath the surface. For this purpose, a special protective tunnel will be used, enabling the structure to be precisely assembled and welded one metre below the water’s surface. The completed dock is due to be handed over to the Gryfia shipyard in July 2027.
The two end sections of the dock are each over 80 metres long. These will house key installations, including two massive pumping stations forming the heart of the ballast system. Two cranes will be installed at the top of the dock’s left and right towers to support ship repair operations.
Thanks to the new 240-metre dock, “Gryfia” will be able to service vessels over 230 metres in length, approximately 36 metres wide and weighing up to 24,000 tonnes. This will enable the shipyard to generate revenue from the inspection and repair of the largest vessels calling at the Szczecin-Świnoujście port complex.
The dock’s versatile design will allow it to service vessels with non-standard weight distribution, such as ro-pax ferries. Additionally, thanks to special recesses at the bow and stern, it will be possible to repair ships equipped with azimuth thrusters, a technology used, for example, on the new “Jantar” ferry.
The “Gryfia” shipyard is fully prepared to accommodate the new structure, which, as Dock No. 8, will become an important part of the yard’s infrastructure. As part of the preparations on the Oder, a dock with a draught of 17 metres was constructed, the quay was modernised and a 57-metre pier was built. The entire investment was complemented by modern energy infrastructure.
The modernisation of “Gryfia”’s infrastructure and the construction of the dock at the “Wulkan” shipyard are largely financed by the state-owned Corporate Development Fund. This investment is of key importance to the local labour market: “Gryfia”, which specialises in repairs and conversions, employs around 450 people, whilst several dozen companies operate on the premises of the “Wulkan” shipyard, providing employment for as many as 2,500 workers in total.
Poland’s docking potential in the Baltic context
The construction of a new dock in Szczecin reinforces Poland’s strong position in the European ship repair market, currently dominated by the Gdańsk Ship Repair Yard.
It is in Gdańsk that the country’s largest floating dock, with a capacity of 33,000 tonnes, has been in operation since the 1970s, enabling the servicing of vessels weighing up to 28,000 tonnes. Gdynia also remains a significant player, where shipyards such as Nauta and PGZ Stocznia Wojenna use docks with a lower capacity, up to 12,000 tonnes, but which are important for servicing the naval fleet and merchant ships.
The new investment by Szczecin-based “Gryfia”, with a capacity of 24,000 tonnes, will not only challenge the current leaders but, above all, fill a significant gap in the western part of the Polish coast, enabling the reception of Panamax-class bulk carriers. As a result, Poland will strengthen its position as a leader in class repairs in Europe, being able to service almost every type of vessel operating in the Baltic Sea
Repair in a floating dock is a precise engineering operation
The process begins with meticulous preparation of the workstation, known as steel-outfitting. At the bottom of the dock, in accordance with the technical documentation for the specific vessel, keel blocks and side supports are positioned. These must perfectly replicate the shape of the hull so that, once the ship is docked, its enormous weight is distributed evenly, preventing structural deformation.
Once the docking bay is ready, the docking process begins. The dock fills its ballast tanks with water, submerging to the appropriate depth, after which tugs precisely guide the vessel into the space between the piers. A crucial moment is the pumping out of water from the dock’s tanks; as the dock rises, the vessel settles onto the supports. Once the dock has been completely raised and the deck dried, the repair crews gain unrestricted access to the underwater section of the hull, which normally remains out of sight.
The actual work begins with a thorough cleaning of the hull using hydro-sandblasting, which removes rust and marine growth. Once the surface has been prepared, modern anti-corrosion and anti-fouling coatings are applied.
At the same time, specialist inspections of the propulsion and steering systems are carried out: the condition of the propeller, shaft seals and play in the rudder bearings are checked. Using cranes moving along the dock’s gantries, specialists replace the bottom valves and service the ballast systems and piping. Once all work has been completed and the classification survey has been successfully passed, the dock is reflooded and the vessel, having regained buoyancy, is moved out into the harbour basin.
A historic event for the maritime sector
The construction of Dock No. 8 is a project of strategic importance, which has the potential to become a new driving force not only for Szczecin’s but also for Poland’s maritime economy. Despite enormous financial and logistical challenges, the investment being carried out by the “Wulkan” and “Gryfia” shipyards proves that the Polish shipbuilding industry is heading in the right direction. Upon completion in 2027, Szczecin will have one of the most modern and versatile docks on the Baltic Sea.
