A guidance on the safe transport of project and break-bulk cargoes, outlining essential measures to mitigate risks associated such shipments.
Break bulk cargo consists of individually loaded goods that are not in shipping containers, typically packed in drums, bags, pallets, barrels, or crates. Examples include machinery parts, steel coils, or coffee bags. Project cargo involves large, heavy, or oversized items that need specialized handling and transport due to their size, weight, or complexity. Project cargo includes items like wind turbine components, oversized pipes, or heavy machinery. They demand special attention throughout loading, stowage, securing, transport, and discharge.
While generally safe for sea transport, these cargoes need thorough planning and risk assessment to prevent shifting or accidents during the voyage. In its guidance, Steamship Mutual has included the following key points for the safe transport of project and break-bulk cargoes:
1 Pre-shipment evaluation
- Vessel selection: Project cargoes carried on general cargo, multi-purpose, heavy lift vessels; container ships, PCTC, or other vessels may be used depending on size, weight, shape, value.
- Planning & coordination: Essential among all parties; includes vessel feasibility study to prevent cargo, ship, environmental damage, and crew injury.
- Crew requirements: Experienced and properly trained for planning, execution, stowage, securing, and care of cargo.
- Vessel feasibility study:
- Assess stability requirements and structural integrity.
- Prepare pre-stowage plan; ensure deck strength limits and ballast system adequacy.
- Check navigation bridge visibility; exemptions may be requested if needed.
- Evaluate navigational acceptability at load/discharge ports and intermediate passages.
- Port feasibility: Verify equipment availability, berth limitations, restrictions, and local rules for safe loading/unloading.
- Cargo handling planning: Consider size, weight, shape; select proper handling aids (flat racks, Mafi trailers, etc.).
- Lifting & securing: Use strong dedicated lifting points; identify center of gravity to prevent damage or accidents.
- Documentation review: Dangerous goods declarations, manifests, packing lists, and manufacturer/shipper instructions must be checked in advance.
2 Carriage of cargo
Having completed a pre-shipment assessment, and prior to the cargo arriving at the quayside, every phase of the operation from loading through to discharge should be carefully planned, with particular attention to the lifting operations.
Lifting operations: Use suitable cranes with appropriate Safe Working Load (SWL). In tandem lifts, SWL is reduced depending on the lift angle. Inspect and verify all lifting and rigging equipment for capacity and certification. Operations should be carefully supervised until cargo is securely stowed. Always use dedicated lifting points; consult the manufacturer if none are available. Avoid rigging around crates directly to prevent damage to packaging or cargo.
Cargo securing and stacking: Ensure individual components are adequately inter-locked or secured when stacked or stowed in composite units or frames. Use sufficient quality dunnage to distribute weight on the deck, prevent sliding, and avoid exceeding deck strength. Follow fumigation or certification requirements for dunnage if required by importing countries. Cargo in or on cargo transport units must comply with the CTU Code.
Vessel-specific handling: Container vessels should carry cargo in holds or on flat racks as advised by the equipment manufacturer. PCTC vessels should secure cargo on Mafi trailers. Deck stowage is allowed only after pre-shipment assessment confirms suitability.
Cargo Securing Manual (CSM) compliance: Secure cargo in accordance with approved CSM. The Master verifies ship stability and securing calculations to prevent movement or damage in adverse weather. Additional fittings must comply with classification society standards for Maximum Securing Load (MSL). Avoid overloading securing points; maintain correct lashing angles. Use lashing equipment of uniform grade and tensile strength; avoid mixing types. Maintain adequate spare securing equipment for replacements or additional securing.
Cradles and bespoke sea-fastenings: Ensure both cargo and cradles are properly secured to prevent shifting due to high centre of gravity. Bespoke sea-fastenings must be made from certified materials with qualified personnel; ensure weld quality. Implement robust risk assessments, safety measures, and permits before any hot work.
3 Cargo care and monitoring
In the event of an adverse weather forecast, safety considerations and advance preparations are essential. Weather routeing advice to account for cargo sensitivity can be an effective tool to anticipate, assess, and mitigate against environmental conditions whilst supporting effective voyage planning, and the development of appropriate contingency measures.
It is also important to ensure safe access for regular monitoring of cargo and securing arrangements during the voyage. Considerations should include expected weather, freeboard and the availability and necessity for walkways, ladders, platforms, guardrails and lighting, as well as work permit requirements such as PPE, atmosphere checks, and ventilation.
Shippers may have specific requirements for certain sensitive cargo in relation to measurement and monitoring of particular parameters such as shock loads, tilt, temperature and humidity, and often provide devices such as single event indicators / labels or more complex data recorders. Event data can potentially assist claims investigators to correctly identify and track an incident timeline.