In brief
In a shipyard, hazards do not occur one at a time but overlap in the same block on the same day: while welding is being done in an enclosed compartment, paint may be applied right next to it, scaffolding may be dismantled outside, and these jobs may be carried out by different subcontractors. That is why shipyard safety requires, in addition to managing each risk with a separate permit, joint planning that prevents jobs from clashing. The principal employer is obliged to coordinate the risk assessment, the emergency plan and committee work with subcontractors.
Why is shipyard safety in Yalova addressed separately?
In Yalova, shipbuilding appears in reports of the East Marmara Development Agency as one of the province's leading economic sectors, and the shipyards are concentrated in Altınova. In a shipyard, the ship is built in blocks, these blocks are joined on the slipway or in the dock, and outfitting, painting and testing follow. Because many subcontractor teams work on the same hull at every stage, shipyard safety is set up differently from OHS in a single factory.
What sets this area apart from other metalwork is that hazards arise not one by one but together. The welder carries out hot work inside a narrow compartment, i.e. in a confined space; the painting team may be using solvents in the tank right next door; outside, scaffolding is being erected or dismantled. This article describes these combined risks and how to manage them on site. We described our service arrangements in Yalova on the Yalova OSGB page; as Yalova borders Bursa, it is within Bursa Sistemer's area of authority.
Welding inside a ship block: hot work and confined space at the same time
Compartments such as double bottoms, ballast tanks, fuel tanks and cofferdams are volumes with no natural ventilation, whose access is limited to a manhole or a narrow hatch. Welding inside a ship block should therefore be subject to both a hot work permit and a confined space entry permit.
| Hazard | How does it arise inside the block? | Basic measure |
|---|---|---|
| Oxygen depletion | Shielding gas (argon, CO₂) is heavier than air and collects at low points | Oxygen measurement before entry and continuously, forced ventilation |
| Oxygen enrichment | A leak in the oxy-fuel gas hose or oxygen being released "for ventilation" | Hose and connection checks; oxygen never used for ventilation |
| Fire and explosion | Previous paint coats, solvent residue, oily rags, flammable gas leaks | Lower explosive limit measurement, removal of combustibles, fire watch |
| Welding fume | Fume concentrates in a small volume | Extraction at source, forced ventilation, suitable respiratory protection |
| Electric shock | Wet and metal surfaces, damaged cables and electrode holders | Cable and holder checks, correct connection of the welding circuit |
| Heat stress | Inside a steel block in the summer sun | Work-rest pattern, water, ventilation |
Apply the following rules on site for this work:
- Gas measurement before the permit and throughout the work: Oxygen, the lower explosive limit and, depending on the nature of the work, toxic gases are measured. Acceptance values should be written in the permit procedure. For the measurement method, see our article on gas testing in confined spaces.
- Gas hoses stay outside the block: During breaks and at the end of the shift, oxygen and fuel gas hoses are removed from the compartment or shut off at the source. A small leak in a hose left inside overnight can turn into a fire at the first spark in the morning.
- Attendant outside: At the entrance to the confined space, there is an attendant who maintains communication with the team inside and keeps a record of who is inside.
- The far side of hot work: The other side of the bulkhead is also checked; paint, insulation or cables behind the plate can ignite.
- Rescue plan: How a worker who collapses will be brought out through the manhole is planned before work starts.
For the sections of the hot work permit, see our article on the hot work permit, and for the basic rules of confined space entry, see our article on confined space entry.
Painting: solvent vapour and explosive atmospheres
Paint application inside tanks and compartments carries the highest fire and exposure risk in the shipyard. Solvent vapour formed during spraying builds up in a small volume and can create an explosive atmosphere. For this reason, under the Regulation on the Protection of Employees from the Hazards of Explosive Atmospheres, compartments where painting is done should be assessed as explosive atmospheres and this assessment recorded in the explosion protection document.
The main measures in painting work are:
- Lighting, fans and hand tools used in the compartment being suitable for explosive atmospheres.
- Ventilation continuing after painting has finished until the vapour has been completely removed.
- Considering supplied-air respiratory protection for employees spraying for long periods in a small volume.
- Recording exposure in the risk assessment and health surveillance according to the paint's safety data sheet.
We explained how to carry out an ATEX assessment in our article on the explosive atmosphere and ATEX document.
Scaffolding, openings and lifting operations
On the slipway and in the dock, the area around the hull is a work-at-height zone. Scaffolding erected along the hull and hatch and manhole openings on the blocks are the main sources of falls.
- Scaffolding inspection: The periodic inspection interval for construction scaffolding is at most 6 months. In addition, scaffolding should be inspected and tagged after erection, after modification and after events such as strong wind; the details are in our article on construction scaffolding inspection and tagging. You can track inspection dates with the OHS calendar tool.
- Openings: Hatch and manhole openings on blocks are protected with covers or guardrails; an opening made temporarily is closed as soon as the work is finished.
- Moving blocks: Overhead cranes, cranes and slings used to lift blocks undergo periodic inspection at least once a year. Nobody stands under the load during lifting; nobody goes under a block before it has been lowered.
- Falling objects: While work is being done on the hull, teams working on the lower scaffold levels and on the dock floor are protected against falling tools and materials.
Dense subcontracting: who manages what?
In a shipyard, most work is carried out by subcontractors. Law No. 6331 and the regulations clearly divide duties in this situation:
| Topic | Principal employer (shipyard) | Subcontractor |
|---|---|---|
| Risk assessment | Oversees subcontractors' work, integrates it with its own work, monitors implementation of measures | Carries out a risk assessment for its own work and gives a copy to the principal employer |
| Emergency plan | Responsible for the workplace as a whole | Responsible only for its own work area and work |
| OHS committee | Ensures cooperation and coordination if there are separate committees | Appoints an authorised representative for coordination if it has no committee |
| Permit system | Sets up and runs a single permit system | Does its work under permit within this system |
| Information | Informs the subcontractor of site risks and rules | Informs and trains its employees |
Legal basis: Art. 15 of the Risk Assessment Regulation, Art. 18 of the Regulation on Emergencies, and Arts. 22/2 and 23 of Law No. 6331. For details of the division of duties, see our article on OHS when working with subcontractors, and for coordination between employers working in the same area, see our article on several employers in the same work area.
A combined risk plan: "same block, same day"
Managing welding, painting, scaffolding and lifting correctly one by one is not enough in a shipyard. To catch the point where risks combine, we recommend the following arrangement:
- Block and compartment inventory: Which compartments count as confined spaces, their access and ventilation options are listed in advance.
- Daily work programme: What each subcontractor will do in which block the next day is collected one day in advance.
- Clash check: Clashes such as painting and hot work in the same block, work on the hull with scaffold dismantling below, or block lifting with work underneath are marked in the programme and permits are issued accordingly.
- Single permit coordinator: All permits go through a single point; the coordinator can see clashes on site.
- Site induction: Every newly arriving subcontractor employee is told the shipyard's rules, the assembly point and the permit system.
- Shift handover: Open permits, equipment left inside and ongoing measurements are handed over in writing.
These risks should appear in the risk assessment not only one by one but also as clash scenarios. Welding fume, grinding noise and solvent exposure are also subjects of health surveillance: hearing tests are mandatory for work where the upper exposure action value of 85 dB(A) is exceeded, and we plan measurements and tests with authorised laboratories and healthcare institutions. For risks specific to welders, see our article on welders' occupational safety risks, and for our general approach in the metal sector, see our metal and machinery page. In its OHS specialist service, Bursa Sistemer sets up the shipyard's permit and coordination arrangements together with the work programme on site.
Frequently Asked Questions
Which permits are needed for welding inside a ship block?
If the compartment inside the block is a confined space, both a confined space entry permit and a hot work permit are needed. The two permits should be based on the same measurements, ventilation, attendant and rescue plan, and closed together.
Who trains subcontractor employees in a shipyard?
Each subcontractor is responsible for the OHS training of its own employees. The shipyard is obliged to inform subcontractor employees of site-specific risks, rules and emergency arrangements and to ensure coordination; this information is usually given through site induction training.
How often is shipyard scaffolding inspected?
The periodic inspection of construction scaffolding is carried out at least every 6 months. In addition, it should be inspected and tagged after erection, after every modification and after events such as strong wind.
Can an OSGB in Bursa serve a shipyard in Yalova?
Yes. OSGBs (joint health and safety units) are authorised to provide services in the province where they are established and in neighbouring provinces; Yalova borders Bursa. The contract and assignment are made through İSG-KATİP (the Ministry's online OHS registration system) in the usual way.
A certified specialist matched to your hazard class: site inspections, approved logbook, training plan, annual plan and report follow-up.
Bursa SİSTEMER OSGB Technical Team — written from the field experience of our OHS specialists and workplace physicians. Legal information is valid as of the publication/update date; contact us for an assessment specific to your business.