The Impact of Removable Media on Maritime Operations

Across today’s maritime sector, removable media such as USB drives present a growing cyber risk to vessel operations and infrastructure. As shipping companies increase their reliance on digital systems, the threat of introducing infected media onto ships is a risk that is often underestimated. Understanding the unique vulnerabilities faced by modern vessels is key to building robust shipboard security strategies that align with current industry practice.

The hidden threat: how USB devices can compromise shipboard safety

USB drives are a common tool for updating electronic chart display and information systems (ECDIS), collecting voyage data, and transferring shore-to-ship documents across the maritime industry. However, these devices can carry malware designed to infiltrate operational technology (OT), disrupt automation, or compromise safety management systems onboard. In 2019, a National Cyber Security Centre (NCSC) report indicated a significant increase in cyber incidents related to infected media, accounting for an estimated 25% of breaches across maritime operations (source: NCSC UK, 2019).

Why ships are particularly at risk

Many vessels combine legacy IT equipment with advanced digital controls, often operating with segments of isolated or poorly connected infrastructure. Crew or contractors may routinely update shipboard systems via portable media, exposing navigation and critical functions to malware that traditional antivirus solutions cannot always detect, especially in air-gapped environments at sea.

The cost of an attack: operational and financial impact

A successful malware incident can disable bridge management systems, disrupt navigation, or leak sensitive data. Maritime cybersecurity authorities warn that a single significant incident can incur losses exceeding millions of dollars, factoring in downtime, incident response, and reputational impact (source: IMO, 2020).

Notable incidents and lessons learned

• ✦ In 2020, a large container ship suffered voyage delays after a critical system infection traced to a contractor’s USB device.
• ✦ A 2017 ransomware variant caused cargo operations in several major ports to halt for days, reportedly originating from a compromised removable disk brought aboard a ship.

Key Takeaways:

• Ships rely heavily on USB drives for system updates and data transfer between shore and vessel.
• Malware on removable media can disrupt navigation, compliance, or safety systems at sea.
• Industry statistics since 2019 confirm rising cyber risks associated with USB device use in shipping.

Best practices for USB security onboard ships

Establishing a strong, vessel-wide policy for USB security forms the first line of defence. Effective measures do not need to be complex; they must be rigorous and consistently enforced. The following are considered industry best practices as of 2024.

Enforce a strict removable media usage policy

Define clear protocols for all crew, contractors, and visitors regarding USB device use onboard. Only authorised, company-provided USB drives should be permitted. All external media must be scanned before use, with activity logged for audit purposes.

Personnel training and awareness

Human error remains a leading cause of cyber incidents. Ongoing cyber hygiene training for seafarers is essential, including practical exercises on identifying suspicious devices, social engineering tactics, and the dangers of using unscanned USB drives found onboard or in port facilities.

Isolated scanning environment for devices

To ensure malware does not reach critical shipboard systems, dedicated devices or kiosks should be used specifically for scanning and sanitising USB media prior to connection with operational networks on the vessel. Scanning stations operating in a quarantined environment greatly reduce the chance of accidental infection.

Key Takeaways:

• Robust USB policies prevent unintentional malware exposure at sea or in port.
• Training all crew and contractors is vital for lasting risk reduction onboard ships.
• Specialised scanning solutions provide a critical physical line of cyber defence.

Aligning with international standards

Leading maritime cybersecurity guidelines require that “all operational systems using removable media are protected by robust scanning and control processes.” Compliance with such standards not only mitigates cyber risk but is increasingly checked by flag states, insurers, auditors, and port state control.

The role of layered security and hardware solutions at sea

Mitigating cyber threats onboard ships is most effective when layered security is applied. Combining procedural barriers, human oversight, and hardware-based solutions ensures malware is identified and neutralised before reaching core navigation or operational systems.

Hardware-enforced security: superior protection for shipboard networks

Unlike software-only defences, hardware-powered scanning stations operate independently from vessel IT infrastructure, creating a physical isolation layer. This approach has seen rapid adoption among leading shipping companies since 2023, addressing advanced threats such as “BadUSB” attacks, which manipulate the firmware of removable devices in ways traditional antivirus software cannot counteract.

Integration into shipboard workflows

Hardware scanning kiosks can be mounted in ship offices or control rooms. Crew or contractors simply insert the USB device, follow onscreen prompts, and receive a clean or contaminated verdict in minutes—no technical background required.

Centralised policy and audit logging

Modern scanning solutions enable remote monitoring from shore and provide an audit trail for every scanned device. This is essential for incident response and meeting auditing requirements under maritime regulations.

Key Takeaways:

• Layered security (policy, human vigilance, hardware defences) best protects against sophisticated malware on vessels.
• Hardware scanners are easy to use onboard and enhance regulatory compliance at sea.
• Comprehensive logging supports maritime audits and investigations.

Case studies: improving cyber readiness in shipping

Protecting a bulk carrier from downtime

In 2024, a leading ship operator implemented a hardware-based scanning system after suffering a two-day voyage delay caused by malware introduced via a contractor’s USB drive. After deployment, incident logs showed a 40% decrease in attempted infections, with no outages since (source: Offshore Energy UK, Q1 2024).

Ensuring safety in vessel operations

A major shipping company adopted a “scan before plug-in” policy using wall-mounted scanning kiosks on board their fleet. During an annual audit, scanned logs revealed several infected USBs prevented from reaching vital navigation and automation systems.

Customising solutions for different vessel environments

Larger vessels or cruise ships often combine portable and fixed scanning units. Portable, battery-operated scanners have proven effective for vessels on short voyages or with limited space, while permanently installed units serve larger ships and fleet operations.

Success Metrics:

• Operators adopting scanning solutions report up to 90% reduction in malware attempts within the first year of implementation on board ships.
• No major incidents attributed to USB use among monitored vessels since the introduction of scanning protocols.

Sector variations within shipping

Certain vessels, such as LNG tankers or navy ships, may demand higher physical robustness and stricter regulatory compliance, while commercial carriers prioritise ease of integration into existing workflows. Remote vessels require ruggedisation and support for offline operation at sea.

Measuring return on investment

With reduced incidents, lower insurance costs, and avoidance of compliance fines, many shipping operators achieve full return on investment in hardware scanning within 12 to 18 months—figures confirmed by reports from the International Association of Classification Societies (IACS), April 2024.

Supporting continuous improvement

Regular policy reviews and data-driven improvements based on logged scanning results help ship operators stay ahead of evolving cyber threats.

Next steps: building a resilient cyber posture in maritime operations

Shipping companies face a shifting landscape of cyber threats linked to USB device usage at sea. Protecting vessels starts with recognising the scale of the problem and combining procedural safeguards, crew training, and hardware-enforced scanning solutions. As risks to digital infrastructure continue to evolve, proactive investment in layered security pays dividends in safety, efficiency, and regulatory compliance.

For detailed, vessel-specific guidance on strengthening protective measures, review available resources on cybersecurity for ships.