Accidents in maritime terminals are caused by known and avoidable risks: uncontrolled equipment movement, unsafe proximity between people and machines, and poor access control. These are not new problems, and they don’t require unproven innovations to fix. The most effective path forward is often a pragmatic one: apply proven technologies, enforce clear processes and maintain a strong safety culture. By taking a layered approach, terminals can significantly reduce risk, improve efficiency and build long-term operational resilience.
Why port safety demands constant attention
Ports and terminals operate under high-pressure, with complex workflows and large-scale equipment movement demanding constant attention to safety. While many have made real progress, contact with moving equipment remains one of the most common causes of workplace harm - affecting people, operations and financial outcomes.
Reducing the risk depends not just on policy, but on consistent execution. Regular inspections, scheduled servicing and structured audits all play a critical role in maintaining performance, identifying issues early and supporting a culture where safety is actively upheld.
Janne Haaksluoto, Director, HSE, Konecranes
A safe terminal doesn’t happen by chance. It takes leadership, clear expectations, and people who look out for each other
Understanding the risk environment
The environmental demands of ports – combining large machinery, time-sensitive operations and rotating personnel – create shared spaces where safety controls must function without exception. This is especially critical where equipment, contractors and third-party personnel operate side by side, often under pressure and across multiple shifts.
Industry data confirms the challenge: during 2022, more than a quarter (27.4 %) of fatal accidents at work in the EU resulted from losing control of a machine, tool or transport/handling equipment (Eurostat via Euronews, 2023) - a core risk in port operations. In the United States, the fatal injury rate in maritime terminals is five times the national average, with nearly 60% of those incidents linked to vehicle or traffic-related causes (U.S. Centers For Disease Control and Prevention, 2024). Further global data shows seafarers are more likely to suffer fatal accidents in port than at sea - reflecting the increased exposure to unfamiliar environments and operational complexity (ILOSTAT, 2023).
These figures reinforce what many terminals already know: meaningful safety outcomes come from clear processes, robust systems, and active risk management at every level of the operation.
The cost of workplace accidents in terminals
In addition to human impact, safety incidents can have wide-reaching effects across terminal operations. Downtime, schedule disruption and damaged infrastructure can all result from a single event. Equipment repairs may cost millions, and areas of the terminal can remain offline while investigations or repairs are underway.
There are also financial consequences. Legal claims following a serious incident may exceed $1 million. In total, insurance claims across the port sector have reached over $341 million within six years – many relating to incidents involving yard equipment (Insurer TT Club, via Freight Waves).
Reputation is equally at stake. Terminals known for strong safety performance earn greater trust from customers and supply chain partners, supporting long-term resilience. On the other hand, inconsistent or reactive safety practices can make it harder to attract and retain skilled workers – especially in roles where operational risk is high and experience matters.
Everyone talks about safety - but what matters is what happens on the ground, shift after shift.
Safety measures in practice
While the risks are known, reducing them depends on consistently applying proven measures. Six areas stand out where practical strategies can be embedded into everyday terminal operations:
- Defining and enforcing restricted working areas
- Reducing direct human exposure to equipment
- Equipment coordination and movement control
- Safety technologies
- Retrofit safety upgrades
- Personnel awareness and monitoring systems
Together, these actions help reduce accidents and associated costs. They also improve flow, reduce legal risk, and support a healthier safety culture – contributing to both operational and reputational strength.
Enhance personnel safety with restricted working areas
The movement of cranes and yard vehicles presents ongoing exposure to risk. One of the most effective ways to manage this is by clearly defining and enforcing restricted working areas. Marking safe and hazardous zones with signage, barriers, and operational protocols helps reduce the likelihood of people entering areas where equipment is active. This is particularly important in high-traffic zones, during shift handovers and in adverse weather conditions.
Mitigate direct human-equipment interaction risks
Reducing the need for people to work near moving equipment is one of the most effective ways to lower contact risk. Automated solutions - such as Automated Stacking Cranes (ASCs), Automated Guided Vehicles (AGVs) and remote operated RTGs – allow high-risk tasks to be performed with minimal human presence. However, in many terminals manual equipment such as forklifts and reach stackers remain an essential part of operations. In these areas, clearly defined work zones and coordinated traffic flows play a critical role in keeping workers safe.
By combining automation with structured manual procedures, terminals can reduce exposure to risk while maintaining flexibility and operational efficiency across the yard.
Coordinate movement with control technologies
Well-planned equipment movement is central to safe terminal operations. Advanced control systems reduce the chances of human error or miscommunication by providing real-time visibility and coordination. Tools such as movement tracking, automated slowdown zones and real-time alerts enable operators to monitor activity across the terminal and respond quickly to any potential hazard. These systems also help maintain smoother flow and reduce congestion during peak periods.
Retrofit existing equipment to boost safety
Not all safety improvements require new equipment. Retrofitting older assets with modern safety features can be a cost-effective way to reduce exposure to risk. Cameras, sensors, collision detection and remote-control upgrades can often be added to legacy cranes, transport vehicles and handling equipment – often regardless of age, or manufacturer. These upgrades help reduce human exposure to high-risk tasks and enhance visibility for operators, while keeping capital investment manageable.
Improve situational awareness with monitoring systems
Personnel monitoring systems help operators and teams stay aware of where people are – and where they shouldn’t be. Technologies such as wearables, RFID tags and geofencing can detect when workers enter hazardous zones and trigger alerts or automatic interactions. Additional sensors mounted on cranes and vehicles can improve visibility in areas with restricted sightlines or complex layouts. By embedding these tools into daily workflows terminals can shift from a reactive to proactive safety mindset.
Not sure where to start? We can help.
Every terminal faces different challenges, but the first step is often the same: identify your highest-risk areas and take practical steps to address them.
With years of hands-on experience across diverse terminal environments, we help you to review your current safety performance, assess the most relevant technology options, and shape a plan that’s realistic, focused and aligned with your operational goals.
