- Three-tonne steel beam fell into bath of molten zinc that created wave that covered worker
- 33-year-old man spent 11 days in intensive care requiring 13 operations
- Wedge Group Galvanizing Limited fined more than £500k after HSE investigation finds chains used to lift beam were damaged and deteriorated
One of Britain’s leading steel galvanizers has been fined more than £500,000 after one of its workers suffered 40 per cent burns to his body when hit by a wave of molten zinc at its site in Devon.
The employee was working for Wedge Group Galvanizing Limited at its site in Marsh End, Lords Meadow Industrial Estate in Crediton, Mid Devon, when the incident happened on 12 October 2021.
Hot dip galvanizing is a process that provides long-term protection against rust and corrosion of steel products. On the day in question, a lifting chain, carrying a roller steel joist weighing nearly three tonnes, failed. The beam fell into a galvanizing bath and the resulting wave of molten zinc covered the 33-year-old, before hitting a wall and surging back along the floor towards him.
CCTV footage from the scene shows the worker alight and running towards the emergency shower where his clothes were removed and he was doused in water. He was initially treated at the scene by paramedics, before being taken by air ambulance to Southmead hospital in Bristol. He had suffered 40 per cent burns and remained in intensive care for 11 days undergoing 13 separate operations. Any remaining healthy skin was grafted to repair his burnt body.
During his lengthy treatment the man suffered infection and sepsis leaving him with multiple long-term health conditions.
An investigation by the Health and Safety Executive (HSE) found that the set of chains used to lift the heavy steel beam had signs of damage and deterioration and there was a failure to withdraw them. Crucially, the chains had not undergone their mandatory regular inspection.
The investigation also revealed that the load slinging arrangement used at the time of the incident was incorrect, which meant that the load being lifted was greater than the safe limit for the chains. The risk assessment in place at the time of the incident for “immersion & swilling” had no reference to checks on chains, or what type of sling configuration to use.
Wedge Group Galvanizing Limited failed to meet several regulations and 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 user manual for the chain manufacturer state that chain slings used in acidic environments, such as zinc galvanising, should be inspected before each day’s use.
The Health and Safety Executive publishes freely available guidance which underlines the importance of thorough inspection of lifting equipment, including the benefits of an ‘examination scheme’.
Wedge Group Galvanizing Limited of Stafford Street, Willenhall, West Midlands, pleaded guilty to breaching Section 3(1) of the Health and Safety at Work etc. Act 1974. The company was fined £566,666 and ordered to pay £15,521 in costs at Bristol Magistrates Court on Wednesday 14 October 2026.
HSE inspector Alexander Ashen said:
“This wholly-avoidable incident led to a young man having to endure truly terrible injuries – and the disturbing truth is that the consequences could have been even worse.
“It is shocking that an industry-leading firm,, with considerable resources at its disposal, should risk the lives of its workers with substandard inspection protocols.
“Our thoughts are with the victim at the heart of this incident, his friends and family, and all those at the site who have been affected by what happened that day.”
This HSE prosecution was brought by HSE enforcement lawyer Gemma Zakrzewski, Paralegal Officer, Farhat Basir and Rowena Goodwin, Enforcement Advocate.
Further information:
- The Health and Safety Executive (HSE) is Britain’s national regulator for workplace health and safety. We are dedicated to protecting people and places, and helping everyone lead safer and healthier lives.
- More information about the legislation referred to in this case is available.
- Further details on the latest HSE news releases is available.
- Relevant guidance can be found here Planning and organising lifting operations – HSE
- HSE does not pass sentences, set guidelines or collect any fines imposed. Relevant sentencing guidelines must be followed unless the court is satisfied that it would be contrary to the interests of justice to do so. The sentencing guidelines for health and safety offences can be found here.