A Midlands company, Bridgnorth Aluminium Limited, has been fined GBP 300,000 (USD 401,451) after a worker sustained serious injuries when a 1.5-tonne hydraulic arm malfunctioned at its Bridgnorth site. The incident took place on 10 May 2023, when the employee was undertaking preparatory activities for the casting of aluminium blocks from molten aluminium.
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The worker, in his early 40s, was kneeling inside a casting mould, inserting ceramic string around the edges while wearing heat-resistant clothing. The hydraulic arm failed above him, with its exterior temperature reportedly around 100°C, causing severe crush injuries.
As per reports, the worker was trapped for three minutes before the mould floor was lowered to relieve some pressure. However, it took an additional 19 minutes before the arm could be fully lifted to allow his safe recovery. Another employee narrowly avoided injury during the incident.
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Investigation findings
An investigation by the Health and Safety Executive (HSE) revealed that the hydraulic arm failed due to a hydraulic malfunction. Although a safety bar was present, it was “not fit for purpose”. HSE found that Bridgnorth Aluminium had not properly assessed the risk of the arm falling and had failed to implement a safe system of work to prevent staff from working beneath it.
HSE inspector Nicola Willcox said, “This was a serious incident that should never have happened. The company subsequently implemented simple control measures to prevent it from recurring. 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 it when it is raised. If these measures had been in place at the time, then this incident would not have happened.”
What is the legal outcome?
Bridgnorth Aluminium pleaded guilty to breaching Section 2(1) of the Health and Safety at Work, etc. Act 1974. The company was fined GBP 300,000 (USD 401,451) and ordered to pay GBP 8,301 (USD 11,123) in costs at Cannock Magistrates’ Court on 13 October 2025. The prosecution was led by HSE enforcement lawyer Edward Parton and paralegal officer Jason Dix, with support from HSE Visiting Officer Natalka Heath.
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