Builders Merchant Fined After Worker Killed in Conveyor Crush

Brief Summary

Huws Gray Limited was fined £2.2 million after a worker died when a colleague started a conveyor while he was inside its framework. The case highlights how relying on instructions and signage without effective guarding can leave operatives exposed to fatal hazards.

What Was The Incident?

On 22 May 2024 at Herringswell Sawmills in Bury St Edmonds, Suffolk, Paul Coulson, a labourer, climbed into the conveyor framework to remove plastic packaging from timber pallets. Another operative, who could not see him, started the conveyor. The timber pack moved and collided with Mr Coulson twice, after the operative reversed and changed direction when the pack did not move as expected. Mr Coulson died at the scene from crush injuries.

What Was The Outcome?

Huws Gray Limited pleaded guilty to breaching Section 2(1) of the Health and Safety at Work etc Act 1974. The company was fined £2.2 million and ordered to pay full costs of £9,929 at Chelmsford Magistrates Court on 26 March 2026.

What Lessons Can Be Learnt?

Use guarding to prevent access, not instruction alone. If a risk assessment identifies access to dangerous parts during normal operation, effective guarding should be in place to stop entry, rather than relying primarily on telling people not to go into the danger area.

Act on evidence quickly, not after an accident. The company had identified employees accessing the conveyor danger zone and had signage, yet CCTV showed repeated entries on multiple occasions between 14 April and 23 May 2024. Further preventive measures were not implemented until after the death.

Ensure conveyor control arrangements cannot restart against an occupied danger zone. Where operators cannot reliably see others from their control position, the system should be designed to prevent starting or re starting equipment while someone could be inside the hazardous area.

Reinforce risk controls with design and operational changes. After the incident, the company introduced conveyor guarding to prevent access, changed the system of work so pallets were unwrapped before being placed on the conveyor, and increased CCTV coverage to improve visibility.

Apply the guarding hierarchy of control for dangerous machinery parts. HSE guidance emphasises that dangerous parts of work equipment should not be accessible during normal operation, and control measures should follow the hierarchy of control, including fixed distance guarding and close guarding where appropriate.

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