Fine For Manufacturing Company After Worker Struck By One Tonne Hopper

Brief Summary

During an improvised unloading of a lorry trailer a one tonne metal hopper slid from forklift forks and struck a worker. The employer had not planned the lift or assessed the load characteristics and had no safe system of work for a non routine heavy lift. The case shows the need for formal lift planning by a competent person for unusual or heavy loads.

What Was The Incident?

On 24 March 2025 workers were unloading steel components from a lorry trailer. They used a forklift with the forks placed under an unsecured metal hopper to lift it from the trailer bed. As the hopper slid from the forks it struck a worker standing alongside it. The worker suffered fractures to skull neck and spine two broken ribs and a severe forehead laceration that required 17 staples and 14 stitches. He spent three weeks in hospital and took seven months off work. The Health and Safety Executive found the lift had not been planned by a competent person the load weight size centre of gravity and lifting points had not been assessed and there was no safe system of work for this infrequent heavy lift.

What Was The Outcome?

The employer pleaded guilty to breaching Regulation 8(1) of the Lifting Operations and Lifting Equipment Regulations 1998 and was fined £300000 and ordered to pay costs of £5690 at Birmingham Magistrates Court on 23 October 2026.

Key Points To Consider

Plan lifting operations. Ensure a competent person carries out and records an assessment of load weight size centre of gravity and lifting points and produces a written lift plan for non routine lifts before work starts.

Use suitable lifting methods. Avoid improvised methods such as using forklift forks under unsecured loads; select lifting equipment rigging and attachments rated for the load and confirm operators are trained in the chosen method.

Control the work area. Set and enforce exclusion zones and a safe system of work so no one stands alongside suspended or unstable loads and review procedures for infrequent heavy or awkward lifts.

HSE Prosecution Link