Decking Manufacturer Fined After Worker Crushed by Improperly Lifted Load
A decking manufacturer based in Stockport and its director have been fined after a delivery driver was seriously injured in a preventable accident involving improper forklift use.
Manchester Magistrates’ Court heard that on 30 April 2019, a HGV driver delivering plastic deck boards to Ultimate Systems Ltd was severely injured when improperly lifted pallets toppled and crushed him. The boards, weighing over 2,000 kg, were stacked on pallets for unloading.
The incident occurred when company director Andrew Kerr used a forklift truck (FLT) to lift the entire stack of pallets at once, despite exceeding the forklift’s load capacity. As a result, the forklift tipped forward, causing the load to fall and trap the driver between the fallen pallets and his vehicle.
The driver sustained serious crush injuries, including spinal damage, multiple rib fractures, a broken collarbone, and a punctured lung. He was hospitalised for six weeks—four of which were spent in an induced coma—and was unable to work for a year due to his injuries.
Health and Safety Failures
The Health and Safety Executive (HSE) investigation found that Andrew Kerr was not trained to operate the forklift truck, and no formal safety procedures were in place at the site for loading and unloading deliveries. Additionally, there were no designated safe waiting areas for delivery drivers during unloading, leaving them vulnerable to incidents like this one.
Ultimate Systems Ltd pleaded guilty to breaching Section 3(1) of the Health and Safety at Work etc. Act 1974 and was fined £38,000, with an additional £3,741.10 in court costs. Andrew Kerr, the company director, also pleaded guilty to the same breach. He was sentenced to 14 weeks imprisonment, suspended for 18 months, along with 180 hours of unpaid work. Kerr was also ordered to pay £3,472.30 in costs.
This case highlights the critical importance of adequate staff training, proper safety systems, and clear rules for all site visitors to prevent workplace accidents and protect employees.
How CQMS Can Help
At CQMS, we understand the importance of maintaining a safe work environment, especially in industries where heavy machinery and high-risk activities are involved. Our team can provide comprehensive risk assessments, staff training, and site safety audits to ensure your business remains compliant and that employees are safeguarded.
Contact us today to learn how we can help improve safety protocols, reduce risk, and ensure compliance with health and safety regulations.