Handling of heavy trolleys

LESSONS LEARNED: The accidents occured during the movement of trolleys, and when parts of or entire trolleys tipped over onto crew members.

This «lessons learned» summary will review three incidents – all reported to the Norwegian Maritime Authority this summer.

How can we learn from these events to prevent similar accidents in the future?

Incident 1

In the first incident, a crew member was moving and preparing trolleys in the work area for tender boats. The crew member's hand was caught between a trolley and a fire hydrant in the work area. The injury resulted in a cut, which was initially treated with first aid on board, before the person was sent to an urgent treatment centre for stitches.

The injured crew member has a short-term absence from work. The shipping company states in its report that this incident will be used as a basis for revising the risk assessment related to transporting trolleys in confined areas.

Incident 2

The secont incident occurred in the galley, where a colleague was assisting in pushing a trolley. On top of the trolley was a loose tray that slid backwards and fell onto the forearm of the employee being assisted.

This resulted in a sprained forearm and a short-term absence from work. The shipping company noted that the tray should not have been placed there in the first place, and that the incident will be reviewed with the crew. In addition, the company has initiated a new risk assessment related to the transport of trolleys in the galley.  

Incident 3

In the third incident, a crew member was placing a trolley into the cold storage room. To make room at the back, all other trolleys were removed and their brakes applied. While entering the cold storage room, the trolley closest to the door tipped over onto the crew member. Colleagues of the injured person were called for assistance.

The submitted report indicates that a combination of the vessel's heeling while departing port and the trolley being heavily loaded (top-heavy) likely caused the tipping. The injured crew member sustained a sprain and cut to the foot, resulting in a short-term absence from work. As with the other incidents, the shipping company has initiated a revision of the risk assessment related to work involving heavy trolleys.

Even routine tasks can lead to unexpected outcomes

The NMA welcomes the fact that these incidents are being followed up with revised risk assessments for work involving heavy trolleys. They serve as a reminder that even everyday tasks – those we think we know well – can suddenly take an unexpected turn.

This isn't necessarily about blame, but about staying aware of the risks that exist in our daily work. Both managers, who are responsible for creating safe working conditions, and crew members, who carry out the tasks, have a roll to play.

Below are some practical tips to support learning and help prevent accidents on board.

What this means in practice

• Crew members: Speak up about near-misses and risky situations before they escalate. Mistakes can happen – what matters is that we share our expeiences so others don't have to go through the same.
• Work environment on board: We support each other in working safely. It's not only okay, but important to say stop if something feels unsafe.
• Management on board: The management on board has a duty to actively promote a proactive safety culture by identifying risks before incidents occur. If something goes wrong, the focus should be on understanding the causes and improving routines – not on assigning blame. At the same time, it is important to be clear about what is acceptable practice and what crosses the line into negligence.
• Shipping company and shore-based organisation: The shipping company and shore-based organisation must ensure that reporting is easy and safe, and that the feedback is actually used to improve operations. A strong reporting culture is one of the most effective tools we have to prevent accidents before they happen.

Practical recommendations:

1. Awareness of hand and body placement

• Keep hands clear of pinch points when manoeuvring heavy trolleys. It is recommended to mark safe hand placement areas on the trolley to help eliminate or reduce the risk of crush injuries. Consider using trolleys with improved ergonomic design to make manoeuvring in confined spaces easier.
• Pause and assess the risk of crush hazards before pushing trolleys forward, especially near fixed installations.

2. Securing loads on trolleys

• No items should be placed loosely on top of trolleys while they are in motion.
• If items must be placed on top of a stationary trolley, use anti-slip mats or secure them properly to prevent movement.

3. Planlegging and teamwork when moving heavy trolleys

• Heavy or unstable trolleys should never be moved alone. Work together when manoeuvring trolleys to prevent tipping or injury.
• Plan the movement in advance, especially in tight spaces or areas where passengers may be present, as they are particularly vulnerable during vessel movements.

4. Ongoing risk assessments

• Risk assessments related to handling heavy trolleys must be reviewed regularly and updated following any incidents.
• They should be actively used in training and included as agenda items in meetings.

5. Vessel movement as a risk factor

• Be especially cautious during heeling, rough seas, or when the vessel is departing port.
• Heavy equipment and trolleys may shift unexpectedly, even if they appear stable when stationary.

Requirements

These events highlight the relevance of current legal requirements for onboard safety and working conditions:

Ship Safety and Security Act 

• Section 21: The working environment on board shall be fully satisfactory.
• Section 22: The company shall establish and follow up a safety management system.
• Section 23: The company shall provide necessary training and instructions.

Regulations of 1 January 2005 No. 8 on the working environment, health and safety of persons working on board ship

• Chapter 3: Requirements for risk assessment and prevention of hazardous situations.
• Section 4-4: Crew members shall receive training in the safe use of work equipment.
• Chapter 7: Special provisions for manual handling of objects.
• Section 7-3: Crew members shall be provided with suitable working conditions for manual handling of objects. This includes sufficient space to carry out the task, a stable and non-slippery surface, and good ergonomic conditions. Crew members shall not be exposed to prolonged or frequent physical strain, especially not alone, if this may lead to injury.

ISM Code

• Section 1.2.2: The company shall ensure safe practices in ship operation and a safe working environment through procedures, risk assessments and training.

Useful links and references

• Luftfartstilsynet: Just culture – rapportering (only available in Norwegian)
• Ship Safety and Security Act
• Regulations on the working environment, health and safety of persons working on board ship
• Forskrift om sikkerhetsstyringssystem for norske skip og flyttbare innretninger - Den internasjonale norm for sikkerhetsstyring (ISM) - Lovdata