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: 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 [...]
Preliminary findings into Chlorine tank incident at the port of Aqaba
A number of tanks containing Chlorine were being loaded onto the MV Forest 6 at the port of Aqaba on 27 June 2022. During the operation, a tank fell and was punctured. The release of Chlorine gas resulted in the death of 13 and injury of more than 250 people. On 3 July 2022, the head of the Aqaba Port incident investigation committee held a press conference announcing initial findings. Please click here for the details We are grateful to the Jordanian Chemical Process Safety Engineers Society for sharing this information. Their original report can be found on LinkedIn : https://www.linkedin.com/posts/jordanian-chemical-process-safety-engineers-society_aqabaabrport-accident-incident-activity-6950927450033827840-eoDB?utm_source=linkedin_share&utm_medium=member_desktop_web . We acknowledge their commitment to sharing learning to benefit others. If you have similar operations, [...]
Serious injury to a crew member, by ship’s crane during operations on a port breakwater
Safety Alert: Serious injury to a crew member, by ship's crane during operations on a port breakwater A general cargo hopper dredger was engaged in the strengthening and lengthening of a port outer breakwater. The vessel’s crane was taking boulders from the cargo hold and placing them in position at the breakwater. The master, who was on duty, went forward to check previously completed maintenance work. On the way back to the accommodation, he decided to check the status of the cargo hold. While checking the cargo, the crane turned towards the breakwater and trapped the master in between the body of the crane and the hatch coaming. The master sustained serious torso injuries. MSIU has issued [...]
Fatality and serious injuries on board a bulk carrier whilst underway
Giulia I departed from the port of Norfolk, USA, bound for Bizerte, Tunisia on 26 January 2021. During the voyage, the vessel experienced inclement weather and the voyage plan was progressively amended, based on the advice received from a weather routeing service. On 29 January 2021, the eductor was started to pump out the water from the forecastle store, which was found flooded. Next day, five deck crew members, including the deck cadet, were instructed to extract the remaining water from the forecastle store and chain lockers, using portable pumps. The vessel’s course was altered to minimize the rolling and pitching and thus, facilitate the safety of the deck ratings. Whilst the crew members were covering the spurling pipes, a [...]
How wide is a Freight Container?
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. Everyone knows a freight container is 8 feet wide. The problem is that this knowledge is no longer entirely correct. “Over width” containers, containers that are wider than 8 feet (2438 mm), are seeing use in more and more trades. Typically these “pallet-wide” containers are about an inch (24 mm) wider than a standard ISO container. This greater width is [...]
Serious injury to a crew member – fall from height in vessel hold whilst underway
A member of the crew was working in a cargo hold, lost balance and fell from a height. This resulted in severe head, back and chest pain. The crew member was air lifted for further treatment. The safety investigation revealed that immediately prior to the fall, the casualty’s safety harness was not secured to a fixed point, whilst he was shifting his position. Please click here for the details We are grateful to the Transport Malta Marine Safety Investigation Unit 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 third parties as appropriate. Please also review any of [...]
Safety Alert: Fumigant poisoning on general cargo vessel with 1 person injured
A stevedore became sick after handling cans containing fumigant while discharging cargo from a general cargo vessel. The stevedore experienced nausea, loss of balance, and nerve damage to his hand; he had an extended absence from work while recuperating. The cargo of bagged sweet potato had been loaded at the port of origin in July 2021. During and after loading, cans and pouches of aluminium phosphide fumigant had been placed between the bags of cargo. The vessel sailed on 19 July. Discharge operations at the destination port began on 10 October. The operation was stopped following the discovery of open cans containing powder. The crew then removed some of the fumigant from the cargo holds. A specialist contractor subsequently [...]
Serious injury to two crew members during an internal fuel oil transfer
Two crew were tasked with the internal transfer of fuel oil onboard a vessel in port. During the operation both crew suffered burns from the hot fuel oil. First aid was immediately provided and eventually, both crew members were transferred to a local hospital. Upon inspection of the engine room, it was observed that the fuel oil spillage originated from an open manhole cover on fuel oil settling tank no. 1. Please click here for the details We are grateful to the Transport Malta Marine Safety Investigation Unit 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 third parties as [...]
Blocked fixed CO2 fire extinguishing system pilot hoses
On 19 September 2021, a fire broke out in the auxiliary engine room on board a roll-on/roll-off cargo ship departing a UK port. In an attempt to extinguish the fire, the ship’s crew activated the machinery space’s carbon dioxide (CO2) fire extinguishing system, but only half of the system’s gas cylinders opened. The initial investigation identified that one of the CO2 system pilot hoses was blocked due to a manufacturing defect. Several coupling leaks were also found in the pilot lines. Please click here for the details We are grateful to the UK Marine Accident Investigation Branch for providing details. We acknowledge their commitment to sharing learning to benefit others. If you have similar operations, please share this information [...]
Lithium Battery Fire – container illegally loaded with discarded lithium batteries caught fire while enroute to a port
On August 19, 2021, a container illegally loaded with discarded lithium batteries caught fire while enroute to a port. The container was intended for a maritime voyage. The batteries caught fire on the highway resulting in loss of the cargo, and significant damage to the shipping container. For full details, please click here We are grateful to the United States Coast Guard 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 third parties as appropriate. Please also review any of your relevant operations for similar hazardous conditions, risks, and controls. Learning content like this is highly valuable as it [...]
Fire Started from Cutting Torch Work
Crew members on a general cargo vessel in port were using an oxy-acetylene torch to remove various sea fasteners, brackets, and cargo securing points from the tween deck pontoons in a cargo hold. Sparks and molten slag from the hot work caused a fire. Thankfully, nobody appears to have been seriously hurt. However the fire damage to cargo exceeded $350,000 including damage from the fire directly, from the smoke, and from the water used to extinguish the fire. Damage to the ship exceeded $100,000 and included damage to the cargo hold bulkhead, access ladders and lighting system. Please click here for the details We are grateful to the American Club for providing details. We acknowledge their commitment to sharing [...]
Fatal fall from overhead crane raised walkway following access panel failure
An electrician was repairing wiring that had been causing a short circuit on the lifting equipment of a large overhead gantry crane. As he was walking along the crane’s walkway, an access panel gave way beneath his feet, causing him to fall through to the ground below. The casualty sustained fatal injuries and was pronounced dead at hospital. An investigation by the Health and Safety Executive (HSE) found the company had failed to maintain the crane walkway’s access panels, which had been used to replace lighting fittings some months earlier. Also, the panel itself had been subject to weld repair, and there was no evidence of any steps being taken to ensure that the panel was safely replaced into the [...]
Falls Not Falling
Since the beginning of 2022, Signal Mutual in the USA has experienced 10 fall injuries resulting in severe injury. This alert lists the ten incidents and includes guidance on fall prevention. We know that falling from height is a significant risk in the cargo industry and that huge effort is put into managing this risk. The information here from Signal Mutual is a valuable and timely reminder to keep ‘fall from height’ firmly on any cargo organisation’s radar. Evaluate work areas together for fall hazards, acting immediately on any identified significant risk and providing an ongoing review of the work areas Manage the risk of falls – start at the top of the hierarchy of controls, eliminate the hazard where [...]
Ship Access
Signal Mutual have been made aware of a near miss incident involving a vessel gangway that was not safely footed on the pier. While re-positioning the hoist line parted, causing the gangway to fall into the water. Please click here for the full Operational Alert We are grateful to the Signal Mutual 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 third parties as appropriate. Please also review any of your relevant operations for similar hazardous conditions, risks, and controls. Learning content like this is highly valuable as it is based on real-world experience. We encourage everyone with publishable [...]