Fitzpatrick Fabrications Ltd, a sheet metal fabrication company based in Lancashire, has been fined £48,000 after an employee sustained a life-changing crush injury and partial loss of his right thumb. The incident occurred on 24 October 2024, at the company’s factory in Nelson, highlighting serious failings in manual handling safety. The firm was also ordered to pay £10,089 in costs at Warrington Magistrates’ Court on 6 October 2026.
Employee suffers life-changing hand injury in preventable incident
The court heard that Mr. Todd Marshall, a welder/fabricator, was working alone to reposition a 133kg stainless steel hopper during a welding task. As he held the larger side of the hopper, which consisted of five component parts, the smaller side slipped on a smooth desk. This caused the heavy structure to fall onto his hand, resulting in a severe crush injury and the partial amputation of his right thumb.
An investigation by the Health and Safety Executive (HSE) revealed that Fitzpatrick Fabrications Ltd had failed to conduct a proper risk assessment for the task. Crucially, no safe system of work had been established, meaning employees, including Mr. Marshall, had not received clear instructions on how to perform the manual handling operation safely. This lack of planning and guidance directly contributed to the serious injury.
Further scrutiny by the HSE uncovered a near-identical incident involving manual handling had occurred at the same factory just days before Mr. Marshall’s injury. This prior event should have served as a critical warning and prompted immediate remedial action, yet no adequate measures were implemented to prevent a recurrence.
Mr. Marshall shared the profound impact of his injury, stating that tasks he once performed effortlessly are now a struggle. He highlighted the devastating effect on his passion for amateur boxing, which he described as his “whole life.” The injury has left him unable to pursue his sporting ambitions, a significant personal loss.
HSE guidance explicitly states that employers must rigorously assess risks associated with manual handling operations. Where hazardous manual handling cannot be avoided, employers are required to implement appropriate steps to reduce the risk of injury. Tools such as the Manual Handling Assessment Charts (MAC Tool) are available to assist businesses in evaluating common risk factors in lifting and carrying activities.
Fitzpatrick Fabrications Ltd, located at Malvern Mill, Waterford Street, Nelson, pleaded guilty to breaching Regulation 4(1) of the Manual Handling Operations Regulations 1992. This regulation places a duty on employers to avoid the need for hazardous manual handling operations so far as is reasonably practicable, and to make a suitable and sufficient assessment of any such operations that cannot be avoided.
HSE Inspector Derek McLauchlan underscored the preventability of the incident, noting its profound and lasting consequences for Mr. Marshall. He expressed particular concern that a similar incident had taken place just days prior, emphasising the company’s failure to learn from previous near misses. Inspector McLauchlan reiterated that businesses must always prioritise the safest methods for manual handling, which includes robust risk assessments and the consideration of available tools like the MAC Tool. He concluded that the fine serves as a stark reminder that the HSE will hold accountable those who neglect their duty to ensure worker safety.
This story was originally published by HSE Media Centre
