£3.8 million after two employees suffered severe chemical burns from caustic soda exposure in separate incidents. One worker tragically lost a leg below the knee, while another required skin grafts after sustaining burns. The Health and Safety Executive (HSE) investigated the significant safety failings at the company’s West Thurrock and Grays sites.
Failings led to caustic soda exposure at two Essex sites
The most severe incident occurred on 6 December 2019 at ICL’s West Thurrock site. Michael Bartholomew, then a chemical loader, stepped into a puddle of liquid suspected to contain caustic soda. The safety boots provided to Mr Bartholomew were not in good condition and failed to offer adequate protection against the corrosive chemical, having not been sufficiently tested against British Standards. As a devastating consequence, Mr Bartholomew sustained serious burns that necessitated the amputation of his leg below the knee. He has been unable to work since the incident.
A investigation by the Health and Safety Executive uncovered multiple leaks of hazardous substances from pipework, valves, hoses, and vessels across the West Thurrock site. Critically, there was no suitable system in place for the inspection, maintenance, and testing of this equipment to prevent or reduce the likelihood of such leaks in areas where workers were present. Furthermore, the systems of work did not adequately account for spillages, and there were insufficient controls for clearing them up safely. The ground around the boiler house was unmade, allowing puddles to accumulate, and designated or enforced walkways were lacking, failing to direct workers safely across the site.
In a Victim Personal Statement, Mr Bartholomew expressed the impact of his injury, stating he felt it was “game over” for his ability to work and support his family. He conveyed a deep sense of loss for his independence and his former work life, which he described as an integral part of his identity. Mr Bartholomew recounted how he could no longer pursue hobbies such as track days or playing football with his grandchildren, activities that had brought him immense joy and connection.
A second incident took place on 30 August 2022 at ICL’s Titan Works site on Hogg Lane, Grays, which has since closed. An employee was manually decanting caustic soda at 50% concentration using a hose into 25-litre containers to top up intermediate bulk containers (IBCs). After completing this task three times, the worker noticed drips from the hose had fallen onto his foot, causing burns that later required skin grafts for healing. Fortunately, this employee has since returned to work.
The HSE investigation into this incident revealed a critical absence of a risk assessment or a documented safe system of work for the manual decanting task. Investigators also determined that the process could have been entirely automated by reactivating an existing automatic IBC dosing plant, which featured fixed pipework and remote control, thereby eliminating the need for manual handling and reducing exposure risks.
Across both sites, the HSE identified a consistent and systemic failure by Industrial Chemicals Limited to properly assess and control the risks associated with handling and containing hazardous substances. This oversight led directly to the severe injuries suffered by both employees. The substantial fine reflects the gravity of these failings and the devastating consequences for the workers involved.
This story was originally published by the Health and Safety Executive.
