The last move of four giants

How APM Terminals Algeciras retired its oldest RTG cranes, paving the way for a new generation of more sustainable equipment

Over several weeks, a meticulously planned operation led by the Engineering Department marked the end of an era at APM Terminals Algeciras. This summer, the terminal completed the dismantling of four Rubber Tyred Gantry (RTG) cranes that had played a key role in container handling and stacking operations in the yard for more than 25 years. The cranes, RTGs 32, 33, 34 and 35, were manufactured by ZPMC and had reached the end of their operational lifespan.

The project began with extensive preparatory work, including the clearance of operational areas, the establishment of safety perimeters, ground conditioning with sand, the removal of auxiliary equipment, and close coordination among the Operations, HSSE, Security and specialised contractor teams. Among them was ActivaLead, one of the pioneering companies in Spain and worldwide in carrying out controlled crane toppling operations in port environments.

The first major milestone came on 13 July with the controlled toppling of RTG 33. A few days later, RTG 32 followed, then RTG 34 and finally RTG 35. The process relied on a carefully engineered technique involving the weakening of the structure at specific points before applying traction forces to bring the crane safely to the ground. A protective sand bed was used to absorb the impact, reducing both costs and operational risks.

Each operation required traffic restrictions, the preventive evacuation of designated areas and a rigorous control system to ensure both personnel safety and the continuity of terminal operations.

And each toppling became an event in itself. In many ways, it was a farewell tribute. Colleagues from the office buildings gathered on the terrace to witness the moment each giant made its final descent. Following every operation, teams proceeded with scrap removal, material recovery and the progressive clean-up of the area until all work was completed in August.

The retirement of these four cranes forms part of the terminal's modernisation and decarbonisation roadmap, which includes the introduction of new hybrid RTGs that are more efficient and environmentally sustainable. These investments support APM Terminals Algeciras' ambition to reduce emissions by 70% by 2030 and achieve climate neutrality by 2040.