This incident report is based on a safety flash published by the International Marine Contractors Association (IMCA), detailing a Lost Time Injury (LTI) that occurred during maintenance work on a capstan aboard a vessel.
What Happened
A crew member sustained a serious hand injury during routine maintenance of a capstan. The incident occurred while the crew member and an officer were greasing the unit. The greasing point was located on the underside of the capstan, requiring the crew member to work in a restricted position.
After the crew member signaled the officer to engage the capstan, the rotating motion caused the crew member’s hand to become trapped between a wire clamp beneath the capstan and the deck. The injury required medical assistance, and the crew member was transported ashore for hospital treatment.
Why It Happened
The injury occurred due to a combination of poor equipment design and unrecognized hazards. Accessing the greasing point required the crew member to lie on their back and reach into a confined area beneath the capstan, where visibility was limited. The design of the grease gun encouraged glove removal, increasing the risk of hand exposure.
A wire clamp on the rotating underside of the capstan—difficult to detect—was not identified in the risk assessment. Despite a toolbox talk and risk-based planning, the crew member’s hand entered the line of fire, highlighting a critical failure in both design considerations and hazard recognition.
Actions Taken
The wire clamp beneath the capstan was removed, and removable fiberglass grating was installed near the capstan area to enhance safety. Grease points were extended to allow access without placing hands beneath rotating equipment. Maintenance procedures were revised to include more precise instructions for work involving rotating machinery and to address risks associated with line-of-fire hazards. A comprehensive inspection was conducted across the vessel and fleet to identify and mitigate similar hazards.
Lessons Learned
- Even with similar equipment onboard, minor design differences can create unexpected hazards. Regular comparison and standardization of equipment layout and access are essential.
- Risk assessments must consider hidden or hard-to-see mechanical components that could pose safety threats during routine operations.
- A review of one hazard may reveal unrelated safety concerns; teams should remain vigilant and responsive to all observed risks.
- Injuries often result from a combination of systemic and design factors. Adequate safety requires addressing both human behavior and engineering controls to eliminate opportunities for harm.
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Source: IMCA
