Poor baler isolation and remote control failure cost worker both legs 26 June 2014

A scrap metal firm and a businessman have been sentenced for serious safety breaches that led to a site worker losing both legs as the doors of a 16-tonne baling machine closed on him.

In May 2011, the 42-year-old worker was dealing with a problem inside the five-metre long baler (scrap metal compactor) at H Ripley & Co's site in Westfield, East Sussex, when the doors of the machine began to close.

Although he tried a remote control to stop them, it failed to respond and, in attempting to escape, the jaws hit his legs with a closing force of up to 180 tonnes, severing one and severely crushing the other.

HSE (Health and Safety Executive) found that the company's isolation procedure for the baler –which it had bought second-hand and fire damaged – was inadequate.

It also found the remote control, built by co-defendant John Platt was flawed. Once the baler doors started closing, the remote control could not stop them. It was also found to be not robust enough for a scrap metal yard.

H Ripley & Co was fined £60,000 with £34,633 costs, while Platt was fined £10,000 with £5,000 costs.

"H Ripley & Co had completely neglected to consider the risks and identify control measures needed to operate the machine safely," says HSE Inspector Stephen Green.

"It had failed to ensure that there was a system to isolate the machine from power before anyone could get inside," he continues.

"It appears that no thought was given to the safety aspects of the remote units for the baler or the way they worked. Had original remotes been sourced or had John Platt manufactured fully functional alternatives, it is likely the incident would not have happened."

Brian Tinham

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Health & Safety Executive

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