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Managing Risks in Stevedoring

Wharf / cargo-handling code. Included in this framework for completeness — Saiyu's day-to-day construction work doesn't intersect with stevedoring directly, but multi-PCBU coordination on a wharf is the same in principle as on a construction site, and several techniques (suspended loads, container stacking, confined-space cargo holds) overlap with construction-adjacent work.

Quick Take
  • Stevedoring serious-incident rate is ~3× the all-industry average.
  • Multi-PCBU coordination between ship operator + stevedoring contractor + wharf operator is the heart of the code.
  • Doggers / riggers require HRWL; competent communication with crane operator is a leading indicator of safe operations.
  • Cargo holds may be confined spaces — apply [[confined_spaces]] permits, testing, isolation, stand-by, rescue.
  • Lashing / unlashing has long been the deadliest task. Never alone; level surface; lashbacks lethal.

1. Scope​

Loading / unloading vessel cargo, stacking on wharves, terminal operations. All cargo types: containers, RoRo, pure car carrier (PCC), break bulk, bulk, passenger.

2. Multi-PCBU framework (the central issue)​

Three primary duty holders with overlapping duty:

PCBUDomain
Ship operatorVessel safety, certification, equipment maintenance
Stevedoring contractorCargo handling, worker supervision, safe systems
Wharf / port operatorInfrastructure, traffic management, facilities

Reg 309-style coordination: pre-arrival planning, shared vessel inspections, exchange of safety information, agreed escalation for outstanding defects.

See [[whs_consultation_cooperation_coordination]] — the principles are identical to a construction site with a Principal Contractor + subbies + utilities.

3. Key hazards & controls​

Falls between vessel and wharf​

  • Hazard: gangway gap, unstable steps, height differences with tide.
  • Controls: ship-shore gangway clear of crane track and load paths; secured; railings; lighting.

Working at height — container tops, hatches, holds​

  • Personnel cradles / work boxes with secondary hoisting and emergency stops.
  • Continuous comms with crane operator.
  • Ladder access in holds: max 6.5 m, 70–80° angle, secured.

Slung / suspended loads​

  • Doggers / riggers HRWL mandatory; assess load condition and sling method before lift.
  • Pre-operational crane inspection.
  • Exclusion zones; SWL verification.
  • Reliable comms (radio + hand signal redundancy).

Mobile plant — forklifts, straddle carriers, reach stackers, RTGs​

  • Traffic management plan; pedestrian / vehicle separation.
  • Speed limits; marked walkways; designated safe standing for truck drivers.
  • Reversing cameras / mirrors / alarms.
  • HRWL operators only; pre-operational checks.

Confined spaces (cargo holds)​

  • Atmospheric testing pre-entry; ventilation; rescue plan.
  • Cargo-related gases: residues from prior loads, fumigation, off-gassing.
  • See [[confined_spaces]].

Container-specific risks​

  • Twist-lock failure, improper lashing, integrity compromise.
  • Visual inspection of twist-locks for damage; compatibility check with plant.
  • Lashing certification (Marine Order 42).
  • Reefer cables: unplugged + stowed before discharge; power isolated during lashing.

Lashing / unlashing​

  • Manual handling strain, lashback injuries (cause of multiple fatalities), double handling, falls on deck.
  • Controls: never alone; positioned to avoid lashback; level, stable surface; hatch covers pinned.
  • Lashing bars never left hanging; rods stored safely off walkways.
  • Two parallel railings around hatches (top + mid-rail, 1 m, taut, 2.5 m spacing).

![[managing_risks_in_stevedoring_img001.jpg|520]] Figure 1 — Lashing-bar storage. Out of walkway, accessible, sorted by length. Trip hazards on deck were a major contributor to past fatalities.

Weather, fatigue, shift work​

  • High winds — crane operations cease (per crane manufacturer threshold).
  • Lightning / poor visibility / rain — work pause + shelter.
  • Heat / UV / cold — PPE, water, breaks.
  • Fatigue management — break schedules, irregular shift handling.

Atmospheric hazards (holds)​

  • Fumigation residues, combustion emissions in poorly ventilated holds, dust from bulk cargo.
  • Ventilation confirmed before entry; SDS access for known cargoes; no combustion engines in poorly ventilated spaces.

Noise (engines, plant, transmission in holds)​

  • Noise monitoring; audiometric testing where exposure exceeds standard. See [[managing_noise_and_preventing_hearing_loss]].

Electrical (reefer containers)​

  • Live cables near work; shock / burn risk during lashing.
  • Power disconnection in proximity; cable management protocols.

4. Special equipment & procedures​

  • Ship-shore gangways: positioned clear of crane track; secured; properly rigged with railings.
  • Securing fittings & lashing: Marine Order 42 compliance; certifications; visual inspection systems.
  • Crane personnel cradles / work boxes: secondary safety system, emergency stops, SWL marked, full-body harnesses, continuous comms.
  • Doggers / riggers: HRWL; sling SWL calculations; load communication.
  • Vessel inspections: pre-arrival checklists; condition assessment of gear, housekeeping, cargo presentation.
  • Emergency plans: site-specific, crew coordination, evacuation procedures, first aid, comms backup.

5. Records & training​

  • Plant register: maintenance, inspection, testing, defect documentation, critical safety instructions.
  • Training records: stevedoring-specific (duties, hazards, incident reporting, communication, plant operation, emergency, PPE).
  • Competency: supervisors, operators, doggers/riggers, plant inspectors.
  • HRWL: dogging, rigging, crane, reach stacker / forklift.
  • Refresher training schedule — workforce is transient; documented induction is essential.

6. Common pitfalls / quick wins​

Do

  • Pre-arrival plan with the ship operator; agreed defect escalation path.
  • Lash / unlash in pairs; dedicated lookout in holds.
  • Tag out damaged lifting gear immediately.
  • Enforce wind-speed cease-work on cranes per manufacturer threshold.
  • Document toolbox talks; track competency for transient labour.
  • Apply confined-space permit + atmospheric test before any hold entry.

Don't

  • Run lone-worker lashing operations.
  • Conceal or defer reporting equipment defects to keep schedule.
  • Skip housekeeping; lashing-bar trips have killed people during vessel motion.
  • Assume the principal contractor (stevedoring contractor) covers your duties — each PCBU retains theirs.
  • Treat reefer cables as inert during lashing.

7. Cross-references​

  • 3C duties (multi-PCBU on a wharf): [[whs_consultation_cooperation_coordination]]
  • Confined-space cargo holds: [[confined_spaces]]
  • Plant: [[managing_risks_of_plant]]
  • Falls (between vessel & wharf, container tops): [[managing_risk_of_falls]]
  • Manual handling (lashing, container handling): [[hazardous_manual_tasks]]
  • Noise (engines, plant in holds): [[managing_noise_and_preventing_hearing_loss]]
  • Glossary (HRWL, dogging, rigging): [[glossary_and_key_concepts]]

Source: managing_risks_in_stevedoring.md (Safe Work Australia, model Code of Practice, CC-BY-NC 4.0). Edition: December 2016. Last verified against SWA: 2026-04-27.