Why this HSE case matters

A recent HSE prosecution is a serious reminder that workplace transport risks remain one of the biggest causes of severe injuries in UK industry.

A vehicle maintenance company in Worcestershire was fined after a worker was crushed under one-tonne concrete blocks during a trailer loading operation.

According to HSE, the worker suffered devastating injuries that later resulted in the amputation of part of his leg.

The investigation found major failures in workplace transport controls, including lack of segregation between workers and vehicles, unsafe loading practices and an untrained forklift operator.

This case matters because similar risks exist across:

• Warehouses
• Logistics operations
• Distribution centres
• Manufacturing facilities
• Construction yards
• Waste and recycling sites
• Loading bays
• Transport depots

The biggest lesson is simple.

If vehicles, forklifts and pedestrians operate in the same area without proper controls, serious incidents become far more likely.

What went wrong?

HSE said the injured worker had been inside an HGV trailer while concrete blocks were being loaded using a forklift truck.

During loading, the forklift truck nudged one of the stacks, causing the concrete blocks to topple onto the worker’s legs.

The investigation found:

• Workers were positioned inside the trailer during loading
• Vehicle and pedestrian segregation was inadequate
• The forklift operator had not received training
• Suitable precautions were not in place
• The company failed to properly manage loading risks

This is not an unusual risk pattern.

Many businesses still rely on informal loading arrangements, verbal instructions or “experienced workers” instead of controlled systems of work.

That approach creates major legal and operational exposure.

Who is affected?

SMEs

Smaller businesses often have limited supervision and fewer formal procedures.

However, workplace transport law applies regardless of company size.

SMEs should ensure:

• Forklift operators are trained and authorised
• Loading zones are controlled
• Workers are segregated from moving vehicles
• RAMS reflect the real task
• Near misses are recorded and reviewed

One serious incident can damage cashflow, insurance, contracts and reputation.

Medium Businesses

Medium-sized organisations often face increased transport complexity across multiple vehicles, contractors and shifts.

The challenge is consistency.

Controls must work across:

• Sites
• Supervisors
• Contractors
• Temporary workers
• Delivery operations

Large Businesses

Larger organisations must demonstrate operational assurance at scale.

This includes:

• Workplace transport audits
• Competence tracking
• Contractor assurance
• Vehicle route planning
• Forklift monitoring
• Incident trend analysis

Weak transport controls can quickly become board-level risks.

Multinationals

Global businesses face additional exposure through:

• ESG reporting
• Supply chain assurance
• Insurance scrutiny
• Multi-site governance
• Procurement frameworks

A major workplace transport incident can affect reputation internationally.

Contractors and Subcontractors

Contractors frequently work in loading bays and shared transport areas they do not control directly.

Before work starts they should confirm:

• Site traffic rules
• Segregation controls
• Loading arrangements
• Exclusion zones
• Communication procedures
• Supervisor responsibilities

No contractor should enter a loading area without understanding the transport risks.

Public Sector Bodies

Public-sector clients and buyers must ensure suppliers can demonstrate safe transport management systems.

This includes reviewing:

• Forklift training records
• Traffic management plans
• RAMS
• Competence evidence
• Audit results
• Incident records

Supplier assurance should focus on evidence, not paperwork alone.

Practical Actions Businesses Should Take Now

1. Review workplace transport risk assessments

Ensure assessments cover forklifts, reversing vehicles, loading operations, pedestrians and exclusion zones.

2. Segregate vehicles and pedestrians

Physical separation is one of the most effective controls available.

3. Verify forklift competence

Only trained and authorised operators should use forklift trucks or loading equipment.

4. Improve loading procedures

Workers should not be positioned in unsafe loading areas during vehicle movements.

5. Use task-specific RAMS

Generic documents often miss real operational risks.

6. Audit transport controls

Regular inspections and internal audits help identify weak practices before incidents occur.

7. Track corrective actions

Record findings, assign responsibilities and close actions properly.

How TPMG Can Help

TPMG helps organisations strengthen operational safety before incidents lead to injury, prosecution or reputational damage.

Relevant TPMG services include:

• Workplace transport safety reviews
• Forklift and loading operation audits
• Contractor and subcontractor assurance
• RAMS development and review
• ISO 45001 internal audits
• Warehouse and logistics risk assessments
• Health & safety training
• Competence management systems
• Incident recovery support
• Operational assurance programmes
• Digital compliance dashboards

TPMG helps businesses move from reactive compliance to proactive risk management.

Need confidence that your loading operations, forklift controls and workplace transport systems are properly managed?

Speak to TPMG about transport safety reviews, contractor assurance, RAMS, ISO 45001 audits and operational risk support.