Safety Alerts
ICHCA International is committed to helping industry to learn lessons fast,
learn them once and make sure that they stay learnt.
This information is intended to provide all organisations in the cargo supply chain with the opportunity to consider the events and to review and adapt their own health and safety control measures to proactively prevent future incidents. We are grateful to all those who provide these alerts and acknowledge their commitment to sharing learning to benefit others.
Learning content like this is highly valuable as it is based on real-world experience. We encourage everyone with publishable information about incidents to send it to us, so that we can raise awareness across the whole industry. Please contact us at secretariat@ichca.com; sharing your insight could save a life or prevent injury.
Safety Alert: Essential to maintain handling equipment, operate safe systems of work and train operators
A mechanic died while repairing a forklift truck. The experienced employee was working with a new employee as they attempted to fix a steering fault on a forklift truck at the firm’s site. While doing this, the mechanic told the new employee, who was driving the forklift truck, to move the vehicle forwards. However, the forklift truck reversed and trapped the mechanic against a trailer. The casualty was taken to hospital with severe head injuries following the incident and placed in an induced coma. An investigation by the Health and Safety Executive (HSE) found that the forklift truck was over 30-years-old and had not been maintained nor subjected to a Lifting Operations and Lifting Equipment Regulations examination for [...]
Safety Alert: Injury resulting in amputation
During operations to load a container to a vessel deck, a ground lock was seen to have moved at the loading location under an incoming container. The vessel Hatch Foreman instructed the crane operator to lift the container such that the lock could be adjusted. As the Foreman was attempting to adjust the lock, the other end of the container came free from its locks causing the container to land trapping the Foreman’s hand / fingers. He called immediately for the container to be lifted. Emergency response (ER) measure were implemented, and the Foremen was transferred to hospital. The outcome was the amputation of an index finger. For the full Safety Alert, Click Here ICHCA International is [...]
Safety Alert: Mooring launch crushed against the side of a container vessel
The aft mooring launch sat at the stern of a containership, waiting for the third line to be lowered to them. Instead, the two lines that had been run ashore and were fast on the bollards were slackened off by the aft mooring team and dumped into the water. The launch tried to move away from the lines to avoid getting tangled. When the launch was almost clear, the ship heaved up on the two lines again, only to catch the mooring launch, lifting it out of the water and crushing against the underside of the ship’s flare. The launch crew were unable to get the crew’s attention despite prolonged shouting and use of their horn. Finally, the [...]
Safety Alert: Familiarising Fire Emergency Responders with Vessels, Ports and Terminals
The investigation has started into the fire on board the Grande Costa D'Avorio - in which two firefighters tragically lost their lives. While we wait to learn from the results, ICHCA Technical panel members have discussed ways ports and terminals may help protect emergency responders as well as crew and port workers in the event of a fire. It is not possible to cover all emergency response planning in a safety alert so we have chosen to focus in this alert on vessel familiarisation. Several members host familiarisation visits with firefighters invited to safely walk a vessel deck and learn firsthand the environments in which they might have to fight a fire. These visits can enhance dialogue between [...]
Safety Alert: Risk assessment, safe system of work and adequate supervision required to prevent unsafe custom and practice in forklift truck operations
An employee’s leg was crushed by forklift truck when he was struck on a pedestrian crossing. The worker had been walking across a pedestrian crossing at the site when a forklift truck, being driven by another worker, collided with him, crushing his leg and ankle. The driver did not slow down while approaching the pedestrian crossing and his vision was restricted as the forklift truck was carrying multiple intermediate bulk containers (IBCs). The injured worker required surgery and skin grafts following the incident. A Health and Safety Executive (HSE) investigation into the incident found that the duty holder failed to provide an adequate risk assessment nor a safe system of work. There was also a lack of appropriate supervision. This [...]
Safety Alert: HSE safety notice Hydrogen Sulphide
There have been a number of significant incidents globally in recent years relating to hydrogen sulphide, either during the discharge of cargo, handling of cargo or as a result of inhalation of the fumes from this cargo. HSE has issued a safety notice after identifying high concentrations of hydrogen sulphide (H2S) in ullage spaces of cargo and slop tanks. Members who may be at risk of hydrogen sulphide exposure are reminded to review SiP 015 – guidance on confined spaces. The high concentrations (up to 16,000ppm) are above the upper measuring limits of the standard portable gas monitoring equipment generally used onboard tankers and floating production storage and offloading (FPSOs) and may be undetected. Hydrogen sulphide concentrations over [...]
Safety Alert: Uncontrolled movement of spreader bar
A vessel was set up alongside a barge in preparation for the subsea deployment of a 16″ (40cm) spool. The spreader bar sea-fastenings were removed by the deck crew and as the crane raised the rigging, the spreader bar rotated uncontrollably causing it to fall from its supports, with the forward end landing on deck and aft end landing on the spool. The potential for rotation was unforeseen; a rigger who was nearby had to move quickly to get out of the line of fire. There were no injuries. Full details here ICHCA International is committed to helping industry to learn lessons fast, learn them once and make sure that they stay learnt. This information is intended [...]
Safety Alert: right lower right leg severed in mooring incident
German Federal Maritime Casualty Investigation report 6/22 examines an incident where a deckhand’s foot became caught in the eye of a mooring line. The eye was lying loose on the ground but was already over a bollard. As the vessel moved, the eye pulled tight on the bollard, severing the deckhand’s foot. The investigation concluded that there was no violation of existing working procedures by any of the people on board. “Inattentiveness during the routine sequence of operations very likely contributed to the accident in this particular case.” The investigators conclude that the post-accident measures by the shipping company, in particular the use of lines with a smaller eye, would have prevented the accident. However at the same [...]
Safety Alert: fumigant poisoning fatality on board a bulk carrier
17 May 2022, bulk carrier Jupiter was at anchor. An ordinary seafarer collapsed while carrying out a routine pre-discharge check on the condition of a soya bean cargo in the hold. Another crew member attempted to help and also collapsed. Both were recovered from the hold by a team wearing breathing apparatus and transferred to hospital ashore. The initial casualty did not survive. The second crew member was hospitalised for 13 days but made a full recovery. The seafarer died as a result of exposure to lethal levels of phosphine gas. The cargo had been fumigated at the load port. The holds were not considered dangerous because the vessel had a gas free certificate, issued by fumigant removal [...]
Safety Alert: HSE safety notice – LPG forklift truck fire risk
The UK Health & Safety Executive has issued a safety notice after becoming aware of a number of fires on liquefied petroleum gas (LPG) powered forklift trucks (FLT) and other similar vehicles that have occurred during starting. The build-up of deposits in fuel systems, in particular, the vaporiser units of LPG powered vehicles has led to a number of fires. Operators should: Review safe system of work in relation to the use of all LPG powered lift trucks and similar vehicles Provide information, instruction and training for all operators about the hazards raised in the alert Park LPG vehicles in well ventilated areas free from flammable material, particularly when parking overnight or for longer periods [...]
Safety Alert: Preventing movement of lorries whilst they are being loaded
An employee died while loading lorry. The victim was operating a forklift truck at the company’s site and was fatally injured when the lorry he was loading was moved by the lorry driver. This pulled the forklift truck over and trapped the forklift operator underneath. An investigation by the Health and Safety Executive (HSE) found that the duty holder’s risk assessment failed to take into account the possibility of lorries moving while they are being loaded. HSE also found that the systems of work provided for ensuring that vehicles were not moved during loading activities were inadequate. HSE inspector John Boyle commented: “This incident could have been avoided by implementing the correct control measures and safe working practices.” https://press.hse.gov.uk/2023/03/30/600000-fine-for-company-after-employee-died-while-loading-lorry/ [...]
Safety Alert: Examining the load, planning the lift and implementing control measures
On 17 August 2018, an employee was helping move a large piece of machinery from one trailer to another at a depot. As the team of workers were moving the piece of machinery, it fell from the bed of the vehicle trailer and hit the employee killing him instantly. An investigation by the Health and Safety Executive (HSE) found that when the workers were transferring the load for shipment, the machinery was in two parts and the smaller section fell free during the lifting operation. This caused the part of machinery to strike the person resulting in immediate fatal injuries. HSE has detailed guidance on the provision and use of work equipment. After the hearing HSE inspector Julian [...]
Safety Alert: Beat The Heat
Working in hot conditions (especially but not only when combined with humidity) can be a serious health threat to workers if the risks are not managed. Signal Mutual in the USA notes that “Every year dozens of workers die, and thousands more become ill while working in extreme heat or humid conditions.” We are grateful to Signal Mutual for sharing this alert about the risks and basic preventive measures. Signal also report that “Over the past three years, more than 70 heat stress-related claims have been reported within the Mutual. Several heat related illnesses (heat stroke, heat exhaustion, heat syncope (fainting), heat cramps, and heat rashes) can affect workers. Some of the symptoms are nonspecific, which means when a [...]
Safety Alert: Timber stacking in ports
The second row of four rows of timber stacked quayside fell, hitting row one. Thankfully, the first row did not then also fall, but this could have resulted in serious injuries to workers and machinery in the area. Key findings: The timber had not been block-stacked, resulting in wide gaps between rows Roundwood was not squared-off at regular intervals Stacks created outside of the reach of stevedores handling machinery Hauliers did not stop work and rectify the spacing of stanchions at time of stacking Recommendations: Members who handle timber cargoes are reminded to review their procedures on timber handling, noting that risk assessments should always be undertaken, and appropriate control measures introduced to ensure safe working for [...]
Safety Alert: Marine Casualty Investigation Board report Arklow Clan
ICHCA International is committed to helping industry to learn lessons fast, learn them once and make sure that they stay learnt. This information is intended to provide all organisations in the cargo supply chain with the opportunity to consider the events and to review and adapt their own health and safety control measures to proactively prevent future incidents. The general cargo vessel “Arklow Clan”, berthed alongside at the Port of Aberdeen, Scotland, United Kingdom (UK) during the afternoon of 11 August 2021, in ballast condition, and scheduled to commence loading a cargo of scrap metal in bulk the following morning. At around 17.49 hours (hrs), three crewmembers commenced lowering the walkway handrails in preparation for loading operations. Whilst [...]
Safety Alert: Seat Belts Save Lives
Over the years, Women and Men in the maritime industry have experienced life altering incidents while operating Powered Industrial Trucks (PIT’s). Despite training, some operators chose to not wear seat belts, at times resulting in injuries. However, there are the ones who chose to wear their seat belts, not for themselves, but for their families and loved ones. They did not allow anyone to influence them to not wear Life Saving Equipment. They chose to go home safe. Click Here for the full Operational Alert We are grateful to Signal Mutual for providing details of this incident and acknowledge their commitment to sharing learning to benefit others. If you have similar operations, please share this information with managers, [...]
Safety Alert: Worker struck by abnormal load during transit
ICHCA International is committed to helping industry to learn lessons fast, learn them once and make sure that they stay learnt. This information is intended to provide all organisations in the cargo supply chain with the opportunity to consider the events and to review and adapt their own health and safety control measures to proactively prevent future incidents. A haulage contractor lorry was transporting project cargo within a port to the vessel location for onward transportation. It collided with a worker carrying out repairs to a damaged roadside lamp. The lamp had been damaged by the same vehicle / driver on a previous transit. Key findings: Cargo components overhung the trailer, exceeding guidelines, no escort vehicle was [...]
Safety Alert: Non-injurious Incident During Pilot Disembarkation
ICHCA International is committed to helping industry to learn lessons fast, learn them once and make sure that they stay learnt. This information is intended to provide all organisations in the cargo supply chain with the opportunity to consider the events and to review and adapt their own health and safety control measures to proactively prevent future incidents. This alert, kindly provided by the Port of Tyne and PSS, addresses the initial findings of an incident where pilot ladder securing on a vessel failed. Luckily, nobody was injured in this instance but it spotlights the vital importance of effectively managing the risks associated with pilot transfer. The vessel’s crew had made fast the pilot ladder and lowered the access [...]
Safety Alert: Lithium battery fire on board MV X-Press Godavari
This Transport Malta report into a fire in a container on the MV X-PRESS GODAVARI while anchored off India, speaks directly to a number of themes that have been firmly present on our radar and in conversations with members over many months. It has better outcomes because there were thankfully no casualties and the vessel was secured. However, the report concludes that matters could have gone very differently in other circumstances. Several findings of the investigation inform topics that we have discussed with members and are summarised below. Please see the full report for details. photograph: Transport Malta report Li-Ion Battery fires - the probable cause of the fire was a short circuit of a lithium-ion battery, due to [...]
Safety Alert: Dropped Cargo – high potential near miss
A Harbour Mobile Crane was in position to begin a discharge of a bulk Maize vessel and the associated Hopper was in the process of being set up in position. The Crane Operator took a grab of maize from the vessel and suspended the full grab near the Hopper for a period of around 15-20 mins whilst the Hopper set up was completed. The Operator began to slew towards the vessel whilst opening the grab, having forgotten that a full grab had previously been taken from the hold, and once the cargo began to fall the Operator immediately closed the grab. However approximately 10 Tons of Maize had already fallen from a height of around nineteen meters damaging the [...]
Safety Alert: Serious Injury – Fall From Height
A Mobile Plant Technician was to conduct routine maintenance work on a Straddle Carrier, simultaneously, the glass floor of the cabin was being replaced due to previous damage. As the Technician entered the cab, he was unaware that the floor grating had been raised with the glass floor removed and subsequently fell some 11m to the ground sustaining serious, potentially life changing, injuries. He remains in ICU. For full details, click here Please click here for previous Safety Alerts: https://ichca.com/safety-alerts We are grateful to the Port Skills & Safety for providing details. We acknowledge their commitment to sharing learning to benefit others. If you have similar operations, please share this information with managers, operatives and any potentially affected [...]
Safety Alert: Elbow Fracture Through Trip on Vessel Deck
A Hatch Foremen working onboard the vessel opened a bar of the access point to the required deck location. As he stepped across onto the deck he tripped over a shin-height safety chain, fell, landing on his elbow sustaining a fracture that required surgery. Direct causes: Safety chain at a low height just above the hatch lid, it was discoloured and not clearly visible. Recommendations: Port based workers to maintain situational awareness and be aware of slip, trip and fall hazards. Task-based risk assessments / pre-job briefings should be reviewed / revised / delivered to ensure coverage of this type of vessel deck situation. For full details, click here Please click here for previous Safety Alerts: https://ichca.com/safety-alerts [...]
Hidden Corrosion on Deck Fittings Can Cause Dangerous failures
The US Coast Guard (USCG) has shared lessons from a marine casualty that resulted in a severe injury to a crewmember onboard a cargo vessel. The incident brought to light a dangerous and potentially fatal situation involving hidden corrosion on D-ring lifting points. Three of four lifting points failed during positioning of a removable hatch cover on the vessel. The resulting snap-back of the lifting sling assembly struck the crewmember in the head. A significant amount of corrosion was found beneath the paint and on the underside of the straps. There were no records of any testing conducted on the lifting points since their installation in the mid-1980s. Nor were there any records of any D-ring replacements, indicating that [...]
Safety Alert: Lifting of ISO Containers and Tanks Using Hooks and Wires
The following has been compiled to provide an overview of some of the safety principles associated with this type of operation. Any lifting operation of this type should be undertaken by competent persons in compliance with applicable regulatory frameworks and is the responsibility of the duty holder. The use of gantry cranes and spreaders is the optimal and preferred method for lifting ISO containers and tanks (collectively referred to as Cargo Transport Units, CTUs) in most situations. However, not all terminals have this equipment available. At some terminals it is therefore accepted practice to lift ISO containers and tanks using wires or chains and single-rope cranes, such as mobile harbour cranes or barge-mounted derricks. Safety should always be [...]
Two catastrophic engine failures, one resulting in a fire, on board a ro-ro passenger ferry
On 26 August 2018, a ro-ro passenger ferry suffered a catastrophic main engine failure as it prepared to enter a river on its regular crossing. This was the ferry’s second catastrophic main engine failure in less than a year, the failed engine being the replacement for the previous failure that had resulted in a fire and serious injuries to an engineer officer. On 14 December 2018, the vessel suffered a third catastrophic engine failure. On this occasion, the failed engine was a new build and had been in operation for just 389 hours.. Safety issues insufficient technical oversight of the engines’ operating parameters standards of maintenance management and quality control engine component and auxiliary system design problems a lack [...]