UK MAIB presents an accident in its safety digest where a foreman fell through a hatch and down two decks to the bottom deck. He was later taken to hospital to be treated as he sustained multiple fractures.
The incident
A dive support vessel was alongside its berth undergoing several periodic surveys. The deck crew had lifted test equipment from the main deck level to two decks below, into a work space. The hatch at main deck level had then been closed but not fastened down in readiness for recovering the test equipment before sailing a few days later. To indicate that it presented a trip hazard, the crew had placed portable stanchions and chain barriers around the hatch, without fixing them to the deck.
A few days later the vessel was about to receive fuel from a bunker barge; during this operation the ship’s crane could not be used. However, tests were complete and the test equipment was ready to be recovered to the main deck. The foreman decided that the lifts could be achieved before the bunker barge was due, and completed a pre-task assessment and safety briefing.
With the crew fully briefed for the task and after knowing their own roles for the operation, the main deck hatch was raised and lifting operations began. The barriers at the main deck hatch remained in place to make sure that crew who were not taking place in the lifts could see the opening. When the bunker barge was sighted making its approach, the foreman stopped the lifting operations, but there was still some test equipment left to move.
To ensure that the vessel was secure and ready for departure as soon as possible after bunkering, the crew continued to move the test equipment manually. Soon there was just a test skid left, which was too large to manhandle. The crew decided to rig a series of two chain pulleys to perform the lift.
The first chain pulley was placed onto the pad eye above the main deck hatch. The second chain pulley was then placed onto the hook of the first, creating the necessary length to lift the equipment up two decks. After a quick toolbox talk, the crew took to their stations. Crewmembers who were required to work inside the chain barriers to work the pulleys’ chains donned safety harnesses with fall arresters before taking up their stations. The foreman was at the main deck hatch outside the chain barrier with a radio along with one crewman.
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As the test skid was being lifted, the foreman took a step to his left to improve his view of the operation. When he did that, the foreman stumbled towards the barrier. He tried to stop himself by grabbing a station, but continued onwards towards the opening. The crewman tried to grab the foreman, but he couldn’t do it so he fell through the hatch and down two decks to the bottom deck, taking the barrier stanchion with him. He landed on his right side and lay prone on the deck. The foreman was immediately restrained by the crew to limit his movement and risk further injury, with extreme consideration to possible head and neck injuries. He was later taken to hospital to be treated, as he had sustained multiple fractures.
- When rigging a barrier for an opening in the deck or when working at height, it is important to consider its effectiveness.
- It is not known what caused the foreman to stumble and fall. Whenever working at height or near openings where there is a risk of falling, vigilance is very important. Consider wearing a fall restraint even if not directly adjacent to the drop.
- Finding alternative ways of working can sometimes lead to a loss of situational awareness. Continuous assessment of how a task is being carried out can identify risks introduced by changes.
- If someone falls from any height should be assumed to have suffered multiple injuries. When it is safe for them to remain where they are they should be kept as still as possible, as was the foreman in this case. Prompt medical advice and examination must be sought. Crew should be well versed in the required actions to be followed through regular, relevant toolbox talks and drills.
