U.S. Coast Guard alert: Essential forklift training to prevent maritime injuries

Eda Zenic -

The United States Coast Guard issued Safety Alert 04-24 reminding about the risks associated with untrained personnel operating powered industrial equipment, such as forklifts, aboard vessels. Specifically, it emphasizes the importance of comprehensive operator training to prevent accidents, injuries, and fatalities in maritime environments. This alert was prompted by a recent incident on a roll-on/roll-off (Ro-Ro) vessel where two crewmembers sustained severe head injuries after an inexperienced forklift operator struck an overhead crossbeam during cargo securing operations.

Key Findings:

The investigation into this incident, along with similar cases, identified a lack of proper training as a major contributing factor. Allowing unqualified or inexperienced crew members to operate forklifts or other powered equipment onboard vessels presents a significant hazard to overall shipboard safety. According to the Occupational Safety and Health Administration (OSHA), forklift-related incidents result in approximately 100,000 injuries annually across various industries, with maritime settings being particularly vulnerable. Studies indicate that enhanced training, retraining, and adherence to proper forklift operation procedures can reduce accident rates by up to 70%.

Regulatory Context:

While OSHA regulations (outlined in Title 29 of the Code of Federal Regulations (CFR), Parts 1915, 1917, and 1918) provide safety standards for powered industrial equipment used in shipyards, marine terminals, and longshoring, there are no specific regulations for shipboard operations involving crewmembers. This regulatory gap makes it crucial for vessel owners, operators, and stakeholders to take proactive measures to ensure safety. The Coast Guard strongly encourages the maritime industry to implement and enforce stringent training standards, even if not explicitly required by law.

Coast Guard Recommendations:

To mitigate the risks associated with forklift operation aboard vessels, the Coast Guard recommends that all vessel owners, operators, charters, and other maritime stakeholders take the following actions:

  1. Review Shipboard Instructions and Standards: Ensure that the safe operation of powered industrial equipment, including forklifts, is covered in key shipboard documents such as the Safety Management System (SMS), Cargo Securing Manual, and other relevant safety protocols. This includes specific procedures for operating forklifts in areas with overhead hazards like crossbeams, which pose an increased risk of accidents, especially in confined cargo decks.
  2. Examine Risk Management Plans: Vessel operators should ensure that hazard identification and risk awareness measures are in place to protect crewmembers. This includes assessing the dangers posed by operating industrial equipment in enclosed spaces and ensuring operators are fully aware of potential overhead obstructions and other hazards that could lead to accidents.
  3. Training and Certification: Although shipboard forklift operation is not explicitly regulated, the Coast Guard strongly advises vessel operators to follow best practices for operator training and certification. The American National Standards Institute (ANSI) standard B56.1-2020 outlines training and certification requirements, load handling procedures, safety features, and forklift maintenance protocols. This standard can be purchased from ANSI and is a valuable resource for developing comprehensive training programs.

Additional Resources:

The Coast Guard provided links to several resources that can help stakeholders improve safety protocols and training procedures, including:

  • OSHA Silica Exposure Publication 3396-06N, addressing Ro-Ro ship and dock safety.
  • OSHA Powered Industrial Trucks Standards, which include operational standards for forklifts.
  • Powered Industrial Truck Operator Training for Maritime, detailing specific training requirements for maritime environments.
  • The ANSI B56.1-2020 standard, which provides guidelines for forklift operator training, safety measures, and equipment maintenance.

Importance of Vigilance:

Investigations and inspections personnel are urged to remain vigilant about the risks associated with unqualified personnel operating powered industrial equipment. The Coast Guard calls on them to take corrective actions as necessary to ensure crew safety. This alert is a reminder that even though the document is informative in nature, it doesn't relieve vessel owners or operators of their legal obligations to meet domestic and international safety standards.