Worker perishes in steel plant accident involving crushing machinery
In a tragic turn of events, Tata Steel has been fined £1.5 million following the death of a contractor, Justin Day, at its Port Talbot steelworks plant in September 2019. The father-of-three and grandfather lost his life while addressing a hydraulic leak on a conveyor system.
The prosecution for the death was brought by senior enforcement lawyer Jon Mack at the Health and Safety Executive (HSE). Tata Steel pleaded guilty to breaching Sections 2(1) and 3(1) of the Health and Safety at Work etc. Act 1974.
At the time of the incident, Tata's Port Talbot plant was the largest steelworks in the UK. The HSE investigation found that Tata Steel failed to ensure the work to replace the lift cylinder was done safely and also failed to properly isolate the conveyor system before Justin returned to address the leak.
The HSE investigation highlighted the need for rigorous isolation, guarding, risk assessment, training, supervision, and management of maintenance activities to prevent incidents such as the fatal conveyor accident. Common safety measures and regulations for maintaining work equipment in industrial settings include:
- Proper isolation of machinery before maintenance: Machinery must be fully isolated to ensure no part remains live or operational during maintenance.
- Effective guarding to prevent access to dangerous moving parts: Mechanical components that can cause harm must be suitably guarded to prevent accidental contact or entry into hazardous areas.
- Comprehensive risk assessment and method statements: Employers must conduct sufficient risk assessments to identify hazards associated with equipment maintenance and put in place safe working procedures.
- Clear procedures and training for workers and contractors: All personnel involved need training and supervision to understand risks and controls around machinery and maintenance tasks.
- Management of ongoing maintenance risks: Companies must manage and communicate the risks arising during multi-stage or overlapping maintenance works, ensuring no unsafe conditions remain when workers re-enter.
- Record keeping of equipment maintenance and safety checks: Accurate maintenance records help monitor equipment safety and assure proper controls are consistently applied.
HSE inspector Gethyn Jones stated that Justin Day's death could have been prevented due to basic health and safety failures. Tata Steel was ordered to pay £26,318.67 in costs at Swansea Crown Court on 31 July 2025, in addition to the fine.
This case serves as a stark reminder of the importance of adhering to health and safety regulations in the workplace, particularly when dealing with work equipment. Employers must ensure they are taking all necessary steps to protect their employees and contractors from harm.
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