Ports and shipyards serve as essential gateways in the global supply chain, facilitating the movement of commodities across the world. However, these environments can also be incredibly busy to the point where safety can be a concern. Boaters and workers have numerous tasks to complete in the loading, unloading and reconfiguration of vessels, as well as traffic management, environmental and weather safety, and incident reporting, among others.
The complex nature of shipyard operations, involving the interaction of large vessels, heavy machinery, and workers, creates an array of safety risks. Accidents in these environments can be fatal if safety is not properly maintained, whether it’s a case of workplace injuries, environmental damage, or financial losses.
Robust safety measures are not just a regulatory requirement, but a fundamental necessity for the efficient and safe operation of these facilities. Failing to do so can cause a wealth of problems, as the recent South Marine Systems case unveiled, with a resultant OSHA fine following a fire.
As such, commercial port and shipyard managers should ensure that vessels can dock safely and that all tasks can be completed with due care and efficiency, without causing undue disruption to marine traffic. Let’s explore some top-level strategies for improving safety in ports.
Enhancing cargo handling safety
Safe cargo handling is pivotal for efficient port operations. Commercial shipyard managers need to ensure the implementation of:
- Regular handling equipment (e.g., cranes, conveyors and forklifts) inspections
- Proper certification and training for equipment operators
- Adherence to OSHA Shipyard Industry Standards
- Rigorous preventative maintenance schedules to identify and report failures or malfunctions
- Strict weight limits on cargo to prevent overloading
- Appropriate methods of securing cargo during handling and transportation
- Advanced load monitoring systems to ensure even weight distribution
- Clear and unobstructed traffic routes for vehicles and pedestrians in the shipyard
- Easy-to-spot signage, markings and safety measures to delineate walkways and traffic lanes
- Comprehensive traffic management plans to minimize congestion and reduce the risk of vehicle collisions
Improving loading and unloading procedures
When docked, vessels require all tasks regarding their loading and unloading to be meticulously planned and executed for maximum safety.
This includes:
- Thorough pre-operation briefings to ensure clear roles and responsibilities
- Weather-dependent operations and alterations
- The placement and correct functioning of required safety equipment
- Clear communication channels between ship crew, dock workers, and supervisors
- Appropriate radio communications to coordinate movements during loading and unloading
- Implementing systems for immediate reporting of safety concerns
- Appropriate personal protective equipment (PPE) including hard hats, slip-resistant footwear and high-visibility clothing
- Emergency response training and simulations
- Buddy systems for high-risk tasks and potentially dangerous situations
Addressing environmental and health concerns
Shipyard managers must also address several health and environmental hazards when coordinating operations in ports to ensure the safety of their personnel and their working environments.
This will involve:
- Taking advantage of EPA funding to ensure clean ports
- Strict hazardous material handling protocols
- Proper storage, transportation, and disposal methods for high-risk materials
- Oily water monitors to detect and prevent water and environmental contamination
- Contamination and spill response plans to address the presence of dangerous substances or accidents
- Emission reduction measures from ships and port equipment, such as emission control systems
- Air quality monitoring solutions to prevent excessive pollutant levels
- Shore power systems for docked vessels to reduce emissions from idle engines
- Sound barriers to prevent excessive noise, where applicable
- Sufficient hearing protection for workers in high-traffic areas
Severe weather safety measures
Harsh weather can drastically affect ports and shipyards, the need for additional safety measures for workers, vessels and the surrounding infrastructure.
These include:
- Advanced, enterprise-grade weather monitoring systems and sensors in line with OSHA recommendations
- Clear protocols for disseminating weather warnings to all relevant personnel
- Evacuation plans for various severe weather scenarios
- Redesigns of port infrastructure to withstand severe conditions, such as flood protection measures and building reinforcement
- Securing loose equipment and materials before harsh weather strikes
- Regular inspections and maintenance of storm drainage systems to prevent flooding risks
- Clear guidelines for vessel movements during severe weather
- Alternative mooring arrangements for vessels docking during storms
- Robust, unambiguous severe weather response plans
Enhancing lighting and visibility
Proper shipyard lighting is vital for safe and effective operations, especially during nighttime or at times when visibility is low.
Port managers should consider the following:
- Regular lighting assessments to identify the areas most in need of sufficient illumination
- Energy-efficient lighting systems that provide adequate coverage and illumination of all essential operational areas
- Task-specific lighting for areas requiring detailed inspection or labor
- Backup power systems or generators to ensure continuous lighting during outages
- Emergency lighting in evacuation routes and offices
- Following OSHA Workplace Lighting Standards
- Regular testing and maintenance of all lighting systems for maximum effectiveness
- Directional lighting to minimize glare and improve worker and vehicle visibility
- Anti-glare measures on reflective surfaces to reduce the risk of impaired vision and subsequent accidents
Incident reporting and emergency response
Rigorous incident reporting and emergency response procedures are pivotal in preventing and minimizing the risk and impact of accidents. The more comprehensive a response plan is, the more likely that future incidents will be contained.
Here are some suggestions:
- Easy-to-use incident reporting tools that facilitate the reporting of safety concerns, near-misses and accidents
- Establishing a non-punitive reporting culture to empower workers to report accidents without fear of reprisal or rebuttal
- Data analysis tools to identify trends and areas for improvement
- Comprehensive response plans for different incidents, such as fires, spills, contamination and medical emergencies
- Regular drills and exercises to test and improve emergency procedures
- Basic emergency response training for all personnel
- Delegating appropriate roles and responsibilities of senior personnel during and after an incident
- Clear reporting lines and communication channels with relevant authorities, from coastguard units to the fire department
Continuous improvement and training
Maintaining a high level of safety and productivity in ports requires consistency and ongoing effort from all parties. This will ensure that safety remains a priority in the upkeep and continuous improvement of personnel and infrastructure, while ensuring supply chains remain unobstructed and free of unnecessary bottlenecks.
Shipyard managers should consider the following:
- Appropriate safety management systems that align with international standards such as ISO 45001
- Regular external and objective safety audits and inspections by approved industry professionals to identify improvements needed
- Employee incentives to participate in shipyard safety programs
- Regular safety training and refresher courses for all employees on essential topics
- Competency-based training programs for specific job roles, equipment and vehicles
- Immersive and scenario-based training programs to reinforce learning
- Regularly reviewing and updating safety procedures based on emerging risks and new legislation
Empowering shipyards for continued safety
Improving safety in shipyards and ports is by no means a straightforward or linear task. It’s a process that requires commitment from the top down, with sufficient time and resources required to achieve this goal.
However, implementing the strategies above will give shipyard management the essentials they need to make their ports inherently safer and more efficient. As the maritime industry continues to navigate supply chain challenges and geopolitical and economic uncertainty, remaining adaptable and vigilant throughout the process will ensure safety does not take a backseat.
In turn, the upheaval will be worth it in the long run, paving the way for more sustainable and viable initiatives that collectively improve the stability and resilience of workers and infrastructure worldwide.
Chester Avey has over a decade of experience in business growth management and cybersecurity. He enjoys sharing his knowledge with other like-minded professionals through his writing. You can connect with Chester by following him on X @ChesterAvey.