Worker Suffers Partial Thumb Loss During Manual Handling Task

Brief Summary

A worker suffered a crush injury and partial loss of a thumb while handling a 133 kg stainless steel hopper component. The employer had not carried out a risk assessment or put a safe system of work in place and workers had not been given clear instructions. The case shows the legal and human consequences of failing to manage manual handling risk.

What Was The Incident?

While welding and assembling a stainless steel hopper made from five parts, a worker was lifting the larger side to reposition it so the next side could be welded. The larger side weighed about 133 kg. The worker was working alone and held the larger side while the smaller side rested on a smooth desk. The hopper slipped and fell onto the worker's hand, causing a crush injury and partial loss of the right thumb. An investigation found there had been no risk assessment for the task, no safe system of work, and no clear instruction to workers on how to carry out the lifting and repositioning. Inspectors also found that a near identical incident had occurred days earlier.

What Was The Outcome?

The employer pleaded guilty to breaching Regulation 4(1) of the Manual Handling Operations Regulations 1992. The company was fined £48,000 and ordered to pay £10,089 in costs, with the sentence recorded on 6 October 2026.

Key Points To Consider

Assess manual handling risks. Review tasks that require lifting heavy or awkward components, record a written manual handling risk assessment, use tools such as the MAC Tool to score common risk factors and consider surface slip hazards and single person lifts.

Put a safe system of work in place. Build a step by step method for repositioning large parts, specify when mechanical aids or team lifts are required, set clear responsibilities and give workers unambiguous instructions before they start work.

Investigate near miss and repeat events. Treat any similar or near identical incident as a trigger for immediate review, carry out a prompt investigation, close out corrective actions and communicate changes to all staff before the task continues.

HSE Prosecution Link