Crate Falls From Forklift Causes Life Changing Injury

Brief Summary

A manufacturing company took responsibility for unloading a heavy crate without adequate planning or supervision and failed to assess whether its forklift was suitable for the load. The crate fell and caused life changing injuries. The case is relevant to health and safety professionals because it shows the risks of non standard lifting operations and the need for clear procedures, equipment checks and effective supervision.

What Was The Incident?

A delivery of a large crate containing an electron microscope, weighing about 1.2 tonnes, was unloaded on site. The delivery partner had originally planned to supply a forklift and driver but, because of restrictions during the COVID 19 pandemic, the site took over unloading. The task was not properly assessed, planned or supervised. There was no assessment of the suitability of the site's two tonne forklift for the load, no clear method defined for how the lift should be carried out, and no defined roles or precautions. A worker was positioned in an unsafe place while the load was lifted, the crate fell from the forklift and landed on him, causing life changing injuries.

What Was The Outcome?

The company was found guilty of breaching Section 3(1) of the Health and Safety at Work etc. Act 1974. It was fined A3230,000 and ordered to pay A3111,000 in costs. The sentence was handed down on 14 September 2026.

Key Points To Consider

Plan and assess non standard lifts. Carry out a documented risk assessment for any lift that is not routine. Review the load weight shape and stability, check lifting equipment capacity and attachments, and set a safe method and sequence for the task.

Clarify delivery and unloading responsibilities. Set written procedures that state whether the site or the delivery partner will unload, who may supervise or guide lifting equipment, and what controls are needed when access to site is restricted.

Provide supervision and verify competence. Assign a trained supervisor for high risk lifts, confirm the competence of anyone involved, establish exclusion zones and safe positions, and make sure the planned method is followed each time.

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