A contractor working in a UK ship repair yard was removing a section of damaged bilge keel by oxy acetylene burning. When reaching the end of his cut the stored energy / stress in the deformed bilge keel caused the plate to release downwards then upwards violently hitting the contractor on the chest, shoulder, jaw and head.

Fortunately, this did not end up with any life changing major injuries but it could have and it was completely avoidable if a task specific risk assessment had been completed.

• All tasks in a repair yard should be fully risk assessed to identify all risks present and not presume or assume personnel (including contractors/sub-contractors) understand all risks associated with tasks.


• Personnel are required to sign off the risk assessment for the task to confirm they have read and understood.


• Repair yards to ensure they have risk assessments in place for “Removing Material under stored energy”


• One-to-one briefing of workers by supervisor or manager to ensure they understand the method statement and associated risk controls.


• Any potential stored energy release tasks must be classed as high risk


• Specific control points are to be put in place to remove damaged hull plating in small sections with all plating / frames under stress marked up with cut lines / cut sequence


• Any plate being removed must be supported / restrained to control any release of stored energy


• Daily project meetings must ensure all high-risk activities are discussed and all associated work is properly planned.