Metal manufacturer fined £300k after worker crushed by hot hydraulic arm

The man, in his early 40s, was working underneath the arm when it failed, resulting in life-changing crush injuries. He had been working for Bridgnorth Aluminium Limited at its site in the town when the incident happened on 10 May 2023.

He was setting up his work to cast aluminium blocks from molten aluminium. He was kneeling inside a casting mould, wearing heat resistant clothing, to insert ceramic string around its edges.

The hydraulic launder arm above the mould, which is used to transport molten metal around the foundry, suddenly fell onto him. It is believed the launder arm was as hot as 100°C.

The hydraulic arm after the incident. Photograph: HSE

The man was trapped for three minutes before the floor of the mould was lowered to release the pressure. However, it was a further 19 minutes before the hydraulic arm could be lifted to allow recovery.

The resulting injuries have had a dramatic impact on his day-to-day life and he has not been able to return to work.

Bridgnorth Aluminium Limited of Stourbridge Road, Bridgnorth, was fined £300,000 for breaching Section 2(1) of the Health and Safety at Work etc Act 1974.

HSE found that the arm fell because of hydraulic failure. While there was a safety bar intended to prevent the arm from falling, it was not fit for purpose. The firm had not assessed the risks of the hydraulic arm falling.

The company has since put in control measures to prevent similar incidents. The process of placing the ceramic string in the moulds is now carried out with the hydraulic arm in the lowered position, and people are restricted from walking under the it when it is raised.

“If these measures had been in place at the time, then this incident would not have happened,” said investigating HSE inspector, Nicola Willcox.