Why these machines are so dangerous

Straddle carriers and reach stackers are classed as powered industrial trucks in U.S. marine terminals, which brings them under OSHA’s Marine Terminals rules and OSHA’s powered-industrial-truck training standard. These rules cover operator qualifications, equipment condition, safe travel, and more.

Intermodal container handling has its own additional rules. OSHA requires, among other things, that containers not be hoisted unless all engaged chassis twistlocks are released, and it sets controls for container yards to protect pedestrians and traffic flow.

On the hardware side, twistlocks interface with the container’s corner castings, which are specified by ISO 1161; container handling and securing methods are laid out in ISO 3874. When a twistlock fails, or is misused, containers can drop or stacks can collapse, with predictable, severe consequences.

What the worst days look like

Tip-overs and rollovers. A reach stacker or straddle carrier loses stability (boom extended, excessive speed, uneven ground, sharp turn) and overturns. Recent safety alerts have flagged tip-overs linked to over-extension and speed.

Struck-by incidents. Pedestrians—often truck drivers or spotters—are run over in mixed-traffic yards with blind spots and poor separation. OSHA and industry guidance emphasize strict pedestrian segregation and traffic controls in marine terminals.

Dropped containers / falling gear. Twistlock failure or improper release can send metal from height. In 2025, ICHCA issued a safety alert after a twistlock dislodged and struck a vessel team leader—illustrating the lethality of small component failures.

Stack collapses. Wind and handling errors can topple stacks. Technical literature and port studies highlight wind as a key driver and the need for conservative shutdown planning as conditions deteriorate.

Common root causes we see

1. Training & supervision gaps. Operators lacking site-specific training; supervisors not enforcing speed/boom limits or ignoring tip-alarm trends.
2. Traffic management failures. No hard separation between people and equipment; unclear right-of-way; poor sightlines; uncontrolled pedestrian activity in stacks.
3. Maintenance and inspection lapses. Worn tires or brakes, derated machines still in service, damaged twistlocks kept in circulation contrary to handling/securement standards.
4. Procedural violations. Lifting with engaged chassis twistlocks; working in wind conditions above the operator’s manual or yard policy thresholds.

Liability: who may be responsible?

The answer depends on where the incident happened and who was involved.

• Marine terminals (ports). Longshore and harbor workers’ injuries typically fall under the Longshore and Harbor Workers’ Compensation Act (LHWCA), which covers injuries on or adjacent to navigable waters in areas used for loading/unloading vessels (piers, docks, terminals). Third-party negligence claims may exist alongside LHWCA benefits (for example, against equipment manufacturers, contractors, or other entities).
• Rail intermodal yards. Railroad employees injured on rail property often proceed under the Federal Employers’ Liability Act (FELA), which requires proof of negligence but allows broader damages than standard workers’ comp. Non-railroad employees (e.g., drayage drivers) may have state-law negligence/product claims against responsible parties.
• Product liability. If a twistlock, spreader, or control system fails due to a design or manufacturing defect or due to inadequate warnings, product claims may be viable (often requiring prompt preservation and expert testing against ISO and other design/strength criteria).

Evidence to lock down immediately

In heavy-equipment cases, speed matters. Critical proof evaporates quickly in busy terminals.

• The machine: Secure the straddle carrier or reach stacker for inspection; capture ECM/telematics downloads, tip-alarm history, fault codes, speed/boom position traces, and maintenance logs. (OSHA’s equipment and training rules make these records directly relevant.)
• Hardware involved: Preserve all twistlocks, corner castings, lashing rods, and spreader components for lab testing against ISO requirements.
• The scene: Yard plans, traffic-control maps, sign/marking schemes, exclusion zones required in container terminals, and any temporary detours.
• People & procedures: Operator certifications, training records, shift assignments, JSAs, radio logs, spotter instructions, and supervision notes.
• Conditions: Weather/wind logs, anemometer data, shutdown thresholds, and any pre-storm yard reconfiguration modeling (often used to justify continuing or suspending operations).
• Cameras & data systems: CCTV, body-worn cams, gate logs, terminal operating system (TOS) and yard-management timestamps.

Prevention that actually works

• Hard separation of people and machines. Marked, enforced pedestrian routes; controlled crossings; permit-to-enter stack lanes; and no-go zones around active lifting. OSHA’s own guidance stresses traffic controls and pedestrian protection.
• Operator competency, refreshed. Site-specific training and periodic evaluations, including blind-spot management, tip-over dynamics, and twistlock release checks.
• Technology with teeth. Tip-alarm monitoring (trend reviews), proximity-detection/collision-warning on straddles and reach stackers, geo-fencing for speed/boom restrictions, and wind-triggered shutdown automation.
• Component control. Twistlock inspection/replacement programs and quarantining damaged devices per ISO-aligned handling practices.

For injured workers and families

These incidents are violent and life-altering. You should not be navigating jurisdictional puzzles while recovering or grieving. An experienced catastrophic-injury team can:

• identify whether LHWCA, FELA, or state law applies;
• secure and test equipment and components before they’re put back in service; and
• develop the human-factors and engineering proof (training gaps, tip-alarm history, wind decisions, traffic control failures) that often decides liability.

Key takeaways

• Straddle carriers and reach stackers are governed by OSHA’s marine-terminal and PIT rules; twistlocks and corner castings are governed by ISO standards – deviations here are red flags.
• The most common killers are rollovers, struck-bys, and dropped loads – often preventable with speed/boom limits, pedestrian segregation, component control, and weather-based shutdowns.
• Early evidence preservation – machine data, twistlocks, training files, and wind/alert logs – changes outcomes.

Hurt in a Port or Intermodal Yard Incident?

The catastrophic injury team at McEldrew Purtell is here to help. We investigate straddle-carrier rollovers, reach-stacker crashes, twistlock failures, and other yard disasters.

Free, confidential consultation. No fee unless we win.

Call 215-545-8800 • Request a Case Review

Available 24/7. We can move quickly to secure the scene, machine data, and equipment.