All about the most important safety measures for RoRo loading

Why safety is the top priority for RoRo loading

The particular risks of the roll-on/roll-off process
RoRo - roll-on/roll-off - is a particularly efficient process in maritime logistics. However, this efficiency also harbours specific risks. Vehicles move over ramps and decks under their own power - often at close intervals and under time pressure. Unlike containerised cargo, there are many moving parts, human personnel on deck and complex coordination processes. A brief moment of inattention can have far-reaching consequences - for people, materials and schedules.

RoRo therefore requires maximum precision, clearly defined processes and well thought-out safety concepts. Every move counts - and every link in the chain has to work.

People, machines and materials: who all needs to be protected

Safety measures for RoRo loading are not only aimed at the cargo itself. The drivers, the terminal team, the crew and the ship itself must also be protected. Damage to vehicles can cost millions - but an accident resulting in personal injury is far more serious.

What's more, the ship as a platform for loading is also a sensitive place. Improper manoeuvres or inadequate securing put a strain on the structure and technology - with potentially catastrophic consequences.

From start to finish: security as a holistic process

Safety doesn't just start on the ramp - it starts at the planning stage. From pre-announcement to delivery and unloading at the port of destination, every detail must be right. Safety measures for RoRo loading are an interplay of technology, people and process management. They only work if they are thought through comprehensively and applied consistently - without compromise.

Before loading: preparation is the first safety factor

Technical control and inspection of vehicles

Before a vehicle even rolls onto the terminal site, it should be technically checked. This includes brakes, steering, lighting and tyre pressure. The condition of the underside is also particularly important - because leaks, oil leaks or loose parts pose an immediate risk to ship safety.

Inspection protocols and checklists help to carry out these checks systematically - and prevent details from being overlooked.

Roadworthiness, fuel level and battery: what must be checked

A vehicle that drives onto the ship must be ready to drive - and reliably so. The battery must not be empty, the tank not full, but also not completely empty. A maximum fill level of 25 % is usually prescribed in order to minimise the risk of fire. In many cases, batteries must be disconnected, especially during long sea voyages or when special dangerous goods regulations apply.

These requirements are not optional - they are mandatory and will be checked by harbour authorities in case of doubt.

Clear communication and documentation before entering the terminal

Information is a key safety factor. Before loading begins, everyone involved - from the driver to the ship's agent - must know exactly what is being delivered, how big it is, what weight it is and whether there are any special features.

Complete and correct documentation forms the basis for a trouble-free process. Unclear information or missing documents not only lead to delays, but can also jeopardise entire loading windows.

During loading: precision, experience and clear processes

Coordination between drivers, loading team and on-board staff

The interaction between all those involved is crucial. Drivers, marshallers and deck officers must communicate precisely - often without much time. Hand signals, radios and defined commands ensure smooth processes.

Loading often takes place under time pressure, but there is no room for rushing. Everyone knows what needs to be done - if clear roles and processes are defined.

Speed, distance and lines of sight - safe manoeuvres in confined spaces

The lanes on RoRo ships are often narrow and the turning circles tight. This makes it all the more important that drivers adhere to the specified speeds and distances. Blind spots and restricted visibility due to the shape of the vehicle or lighting conditions also require a high level of attention.

Guidance systems, markings and ramp lighting help, but are no substitute for anticipatory driving. Particularly critical: reversing on decks - teamwork is required here.

Hazards from slopes, ramps and slippery surfaces: how to minimise the risk

Moisture, oil residue or smooth steel surfaces significantly increase the risk of slipping. Ramps quickly turn into dangerous zones, especially in the event of precipitation, cold or high humidity. Anti-slip surfaces, drainage systems and regular cleaning can help here.

In addition, vehicles should be parked at a sufficient distance from each other and in a stable position to prevent chain reactions in the event of ship movements.

Load securing: the central component of safety

Use lashing systems, lashings and securing points correctly

A correctly secured load is the backbone of every safe RoRo shipment. Vehicles are secured to defined points on the deck using lashing straps, chains or tensioning systems. It is not just the number of lashing points that is important, but also the correct positioning and direction of pull.

Professional lashings keep the cargo in place even in heavy seas - provided they are used correctly.

Different requirements depending on vehicle type and weight

A sports car is secured differently to a 40-tonne excavator. The type of securing depends on the vehicle type, body height, centre of gravity and weight. Rolling machines that cannot brake on their own also require additional measures - such as wedges, blocks or chains.

Special transports such as "static cargo" - i.e. goods that are not ready to travel - often require customised securing concepts, including transport racks or platforms.

Visual inspection and double securing before departure

Before the ship sets sail, each cargo unit must be checked again. Are all lashing points in place? Are all straps tightened? Have the wheels been wedged? A final visual check is the only way to rule out undetected faults or subsequent loosening.

If in doubt, it is better to check too much than too little. Safety does not tolerate haste - and no exceptions.

Organisation and training: safety needs clear rules and trained personnel

Standardised safety protocols for all parties involved

A uniform standard for safety measures during RoRo loading is essential. Clear protocols, comprehensible instructions and defined processes ensure that the right action is taken even in stressful situations. From the journey to loading to leaving the ship - every phase should be documented and visible.

These protocols are not only helpful internally, but also fulfil the requirements of authorities, insurers and customers.

Regular training and instruction for loading teams

Knowledge becomes outdated - especially in the fast-paced world of logistics. It is therefore crucial that all employees receive regular training on new safety regulations, technical updates and best practices for handling unusual freight.

Practical exercises, simulations and feedback sessions increase confidence in the event of an emergency - and create a shared sense of responsibility.

Clearly assign responsibilities and competences - who checks what and when

Safety only works with clear responsibilities. Who is responsible for the delivery? Who checks that the vehicle is ready to travel? Who documents the security? Everyone involved should know their tasks - and carry them out reliably.

This is the only way to create a closed safety net that won't tear - even when things get hectic.

Conclusion:

Safety measures during RoRo loading are not a minor matter, but the central component of successful transport. Those who take them seriously not only protect cargo and people, but also create trust - among customers, partners and crew. Safety is not an expense, but an investment in quality and sustainability.