A 21-year-old employee suffered life-changing injuries at a waste and recycling company yard after being crushed against a brick wall by a reversing telehandler.  He was hand-sorting waste alongside other workers when the telehandler reversed into him.  He sustained multiple fractures, internal organ injuries, nerve damage, partial hearing loss, and permanent sight loss in one eye.

KEY FINDINGS

Key findings from the HSE investigation:

• No suitable and sufficient risk assessment had been completed for vehicle–pedestrian interactions within the yard.
• No segregation between pedestrians and mobile equipment; workers routinely operated on foot in the same areas as vehicles.
• The telehandler had missing reversing mirrors, significantly compromising rear visibility.
• The company failed to implement physical protection or designated pedestrian routes, placing employees at consistent risk.

The company was fined for breaching the Health and Safety at Work etc. 

HOW COULD THIS HAVE BEEN AVOIDED

• Effective Traffic Management Plans, segregate pedestrians and vehicles, and enforce one-way systems and designated equipment operating zones.  Apply temporary exclusion zones with barriers when work activities require pedestrian access.
• Operate documented maintenance schemes, including daily pre-use checks.  Rectify defects promptly, especially those affecting visibility.
• Fit visibility aids where identified by risk assessment, such as mirrors, cameras, sensors, reversing  alarms.
• Ensure all operators are trained, competent and authorised and provide periodic refresher training.
• Consider mandating high-visibility trousers and tops, not just vests.
• Risk assess all tasks involving vehicle and pedestrian interaction..
• Establish safe zones where workers can stand when vehicles are moving.

KEY REVIEW POINTS:

• Review traffic plans, ensuring physical segregation where feasible.
• Verify all mobile equipment has the required visibility aids and that defects are rectified immediately.
• Reinforce operator competence and authorisation procedures.
• Mandate high-visibility PPE
• Require pre task risk assessments for activities in operational yards.
• Audit compliance regularly, including daily equipment prestart checks and  pedestrian route adherence.

For more details, refer to the HSE Press Release:: Recycling company fined after employee suffers life-changing injuries in telehandler incident – HSE Media Centre