Wedge Group Galvanizing Limited has been fined £566,666 and ordered to pay £15,521 in costs after a worker suffered 40 per cent burns to his body when struck by a wave of molten zinc. The incident occurred on 12 October 2021 at the company’s site in Crediton, Mid Devon, leading to a prosecution at Bristol Magistrates Court on 14 October 2026.
Employee sustained 40% burns from molten zinc wave in Devon incident
The 33-year-old employee was working at the Marsh End, Lords Meadow Industrial Estate site when a critical failure in lifting equipment led to the severe injury. A three-tonne steel roller joist, being carried by a lifting chain, unexpectedly fell into a galvanising bath. This caused a powerful wave of molten zinc to surge outwards, engulfing the worker and subsequently hitting a wall before returning towards him. CCTV footage captured the moment the worker caught fire, immediately running towards an emergency shower for urgent dousing and removal of his burning clothes.
Following the incident, paramedics provided initial treatment at the scene before the worker was airlifted to Southmead Hospital in Bristol. He spent 11 days in intensive care, undergoing 13 separate operations to graft healthy skin onto his burnt body. The extensive injuries led to severe complications, including infection and sepsis, leaving him with multiple long-term health conditions that continue to impact his life significantly.
An investigation by the Health and Safety Executive (HSE) uncovered serious failings in the company’s safety protocols. It was determined that the set of chains used to lift the heavy steel beam exhibited clear signs of damage and deterioration, yet they had not been withdrawn from service. Crucially, these chains had not undergone their mandatory regular inspection, a fundamental requirement for ensuring the safety of lifting operations.
Further findings from the HSE investigation revealed that the load slinging arrangement employed at the time of the incident was incorrect. This meant that the weight of the load being lifted exceeded the safe working limit for the specific chains in use. Additionally, the risk assessment in place for “immersion & swilling” procedures lacked any reference to essential checks on lifting chains or guidance on appropriate sling configurations.
Wedge Group Galvanizing Limited was found to have breached several key regulations and industry standards. Under the Lifting Operations and Lifting Equipment Regulations (LOLER) 1998, lifting accessories must be thoroughly examined by a competent person at least every six months. Both the Lifting Equipment Engineers Association (LEEA) code of practice and the chain manufacturer’s user manual explicitly state that chain slings used in acidic environments, such as zinc galvanising, should be inspected before each day’s use. The HSE provides comprehensive, freely available guidance that underscores the critical importance of rigorous inspection for all lifting equipment, including the benefits of a robust ‘examination scheme’.
Wedge Group Galvanizing Limited, based in Stafford Street, Willenhall, West Midlands, pleaded guilty to breaching Section 3(1) of the Health and Safety at Work etc. Act 1974. HSE inspector Alexander Ashen commented on the case, highlighting the entirely preventable nature of the incident and the devastating consequences for the young man involved. He expressed shock that an industry-leading firm, with substantial resources, would compromise worker safety through substandard inspection protocols. The inspector emphasised that the victim and his family remained at the forefront of their thoughts throughout the investigation.
This story was originally published by HSE Media Centre
