M2496 - Chemical injury to the crew

Initial Report

An engineer was changing the chemical additive for the sewage treatment plant. While completing the operation, the chemical spilt, causing chemical burns to the crewmember. The crew member was not wearing any protective clothing and had not considered the risks involved in this operation. The crewmember immediately left the area and went to their cabin to remove the contaminated clothes and take a shower to wash off any chemicals.

A procedure was in place for handling hazardous substances and conducting a risk assessment.

The procedure required PPE, including a face visor, gloves, overalls and a chemical apron. Material Data Sheets need to be consulted before commencing the task, including briefing the crew on their contents and which instructions to follow. The engineer did not follow the procedure. They received refresher training following the event.

CHIRP Comment

This report highlights a breakdown in procedural compliance during a task involving hazardous chemicals. Although procedures and a risk assessment were in place, the crew member failed to wear the required personal protective equipment (PPE) or consult the relevant safety data before commencing the task. This underscores a critical point: safety documentation alone does not prevent harm—it must be understood and actively applied.

The engineer’s prompt and appropriate response following the exposure likely mitigated the severity of the injury.

Familiarity with routine tasks can lead to an underestimation of risks, particularly when hazardous substances are involved. Complacency in such cases can have serious consequences. This report serves as a clear reminder that safety procedures are not optional.

Familiarisation training must fully address the risks associated with chemical handling, including the personal, physical, and psychological safety aspects. The correct use of PPE is not a procedural formality—it is a critical safeguard. It must be consistently applied with the same seriousness as any other essential safety measure.

It is encouraging that refresher training was conducted after the event. However, further reflection is warranted to understand why the procedures were not followed in the first place. Was there time pressure? Were the instructions unclear? Did assumptions override caution? Effective learning from this incident should go beyond retraining and seek to identify and address the underlying conditions that contributed to the lapse. Doing so will help strengthen a proactive and resilient safety culture.

Local practices – unless cases like this are highlighted, they can become the norm.

Complacency – the risk of underestimating liquid chemicals is potentially very hazardous.

Capability – training in the safe use of chemicals should be part of all crew familiarisation. Until familiarised, the crew should not be handling them.

Key Takeaways

For Seafarers, Shortcuts hurt; safety is part of the job.
Follow the procedures, wear the PPE, and don’t guess with chemicals. If in doubt, ask. Reporting protects everyone, including you.

For Managers, What gets supervised gets done safely.
Embed procedures into daily practice, not just paperwork. Reinforce safety behaviour through presence, guidance, and learning from incidents.

For Regulators, Policy is potential, practice is protection.
Focus on how rules work onboard, not just in manuals. Support training, reporting, and visible follow-through to keep learning alive.