Table of Contents
Introduction
In maritime shipping, a single misdeclaration can turn routine journeys into disasters. This was the case when a container, declared safe, actually carried a dangerous chemical and ended up causing a fire onboard. In this article, we dissect how a misdeclared container caused a fire, what decisions were taken, and how future incidents like this can be avoided. The aim: make the complex simple, for students and marine professionals alike.
What Happened: The Incident Overview
Early Warning Signs
One early morning, the ship’s bridge officers observed smoke emerging from the forward section of the vessel. Simultaneously, the fire detection alarm for cargo hold 3 sounded. The Master initially described the smoke as white, then greyish; the Chief Officer saw it as “dark grey, almost black.”
Ventilation fans in the cargo holds were shut down (some were already non-operational). Natural ventilation was present because vent covers were open. As smoke thickened, crew members closed the vent covers for hold 3. No one entered the hold at that time.
Firefighting Measures Taken
The ship diverted to a nearer anchorage. The Chief Engineer discharged almost 200 CO₂ cylinders into cargo hold 3 the full complement required by design which appeared to suppress the fire.
However, smoke reappeared after a few hours. The crew again released more CO₂: 50 cylinders, then another 50 as the smoke persisted. Later, temperature checks indicated a rise inside hold 3, so an additional 5 cylinders were released close to midnight. The next morning, more CO₂ was released.
When salvors arrived, they measured the bulkhead to cargo hold 2 (adjacent) and found 80–83 °C. Deciding that flooding would help, they filled hold 3 with water from fire hydrants. The water level rose up to three container tiers, and after some hours the fire was deemed extinguished.
Root Cause: How the Misdeclaration Led to Disaster
The Hidden Cargo
The container where the fire originated had been declared as non-dangerous. In reality, it contained calcium hypochlorite, a chemical that, under certain conditions, decomposes and releases oxygen, heat, and possibly supports combustion.
The shipping manifest allowed the container to be loaded into the cargo hold under the (false) assumption that the contents were benign. But because it was misdeclared, it ended up stowed in a location it should not have below deck, in proximity to other containers, with limited ventilation.
Self-Heating & Thermal Runaway
The danger with materials like calcium hypochlorite is that they can slowly decompose and generate heat. In a confined container, heat might build up internally. If it cannot dissipate, the rate of decomposition increases a feedback loop. This is called thermal runaway.
Over time, this internal heating can reach a point where combustion becomes possible, even without an external spark. When the heat couples with surrounding packaging or adjacent cargo, fire can engulf broader areas.
Misplacement in the Stowage Plan
Because the container was misdeclared, it was allowed to occupy a stowage position not suitable for oxidising or unstable cargo. That meant less allowance for cooling, venting, or separation from heat sources.
In short: the chain of error was
- Cargo misdeclared →
- Wrong stowage decisions →
- Inadequate cooling/venting →
- Self-heating and decomposition →
- Fire ignition →
- Fire spread
Incident Dynamics & Challenges in Response
Smoke Characteristics & Detection
The smoke’s changing colour (white → grey → dark) hinted at evolving combustion. Early detection was by the ship’s fire alarm system.
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Ventilation Control
Stopping fans and closing vent covers helped limit air supply to the fire zone. But natural ventilation had been active earlier. The crew had to isolate the fire zone without starving safe areas of fresh air.
Use of CO₂ Flooding
CO₂ flooding is commonly used in cargo hold fires to displace oxygen. But here it was not a one shot fix. The fire re-ignited multiple times, requiring repeated CO₂ releases.
Water Flooding as Final Measure
When temperatures remained high and smoke persisted, salvors used flooding. Water is more aggressive and ensures heat absorption, but it also introduces risks: stability, compartment flooding, and collateral damage.
Spread to Adjacent Holds
Temperature data showed significant heat transfer across bulkheads. Fire had already transferred or threatened neighboring holds.
Key Lessons & Prevention Measures
1. Honest & Accurate Declaration
No shortcuts. If cargo is hazardous or potentially reactive, it must be declared under the IMDG Code or other relevant regulations. Misdeclaration is often the root of disasters.
2. Proper Stowage & Segregation
Once known, dangerous cargo must be stowed in positions that allow ventilation, temperature control, and safe separation from incompatible goods. It should not be hidden deep in holds where risk of heat buildup is high.
3. Monitoring & Temperature Checks
Regular temperature monitoring of containers and adjacent holds can reveal early thermal trends. If a container shows abnormal heat rise, it must be isolated and inspected.
4. Fire-Response Preparedness
CO₂ systems, fire dampers, detection systems, vent controls all must be maintained and ready for use. Drills should cover repeated fire re-ignitions and worst-case scenarios.
5. Risk Assessment & Safety Management System (SMS)
A company’s SMS must include checks for misdeclared cargo, audit procedures, review of booking documents, and cross-validation of cargo data.
6. Training & Awareness
Shippers, freight forwarders, and crew all need training. A shipper might misdeclare due to lack of knowledge or cost pressure. Everyone in the chain should know the consequences.
7. Insurance & Regulatory Pressure
Misdeclared cargo fires cost insurers billions annually. Industry pressure and stricter penalties push correctness.
8. Watch High-Risk Cargoes
Some cargoes are repeatedly involved in container fires when misdeclared: charcoal, lithium-ion batteries, calcium hypochlorite, cotton/wool, seed cake, etc.
Broader Context & Other Examples
- In one high-profile case, a container declared as coconut pellets turned out to be charcoal, likely causing fire on Yantian Express.
- Global insurer data estimate that fires from misdeclared cargo cost over USD 500 million annually in losses.
- Studies have found that in inspections, 6.5% of containers had misdeclared dangerous goods.
These examples show that what happened in this case is not unique. The system is under strain: volume is high, inspections limited, and pressure to reduce cost is high.
What Might Be Critiqued — A Balanced View
- The ship’s crew responded reasonably given the data they had. Releasing CO₂, isolating vents, diverting these are standard practices.
- But repeated re-ignitions show that initial suppression may not always work; logic should always allow fallback plans.
- Flooding with water is drastic and has risks (vessel stability, electrical systems, cargo damage), so it’s often the last resort.
- The root fault is often far upstream: at the shipper, logistics, or documentation level. A ship’s crew can’t control what’s unknown to them.
Practical Steps for Students & Professionals
- Learn IMDG Code — know how different classes of dangerous goods are handled.
- Practice real-case drills — simulate “fire in cargo hold due to misdeclaration.”
- Audit booking & cargo papers — cross-check paperwork, ask for MSDS (Material Safety Data Sheets).
- Temperature & gas monitoring — install sensors, alarms, logging.
- Chain accountability — enforce checks at shipper → forwarder → carrier → vessel.
- Incident review culture — when small anomalies arise, don’t dismiss them.
Conclusion
One misdeclared container triggered a chain reaction: hidden chemical reactivity, improper stowage, limited ventilation, thermal buildup, fire ignition, repeated suppression attempts, and finally flooding. The human factor’s dishonest or mistaken declaration was the linchpin.
But this is not just a story. Its lessons should be woven into every step of maritime operations: booking, documentation, stowage planning, risk assessment, firefighting readiness, and training. The vessel crew can only respond to what they know; the real defence is making sure that “dangerous cargo” is never invisible.
