A recent prosecution by the Health and Safety Executive highlights the serious consequences that can arise from poorly planned lifting operations and inadequate control measures.
In May 2026, an engineering company was fined £170,000 following an incident where an employee suffered life-changing hand injuries during a lifting operation involving a forklift truck.
The incident occurred while a three-tonne machine was being lifted at the company’s manufacturing facility. During the operation, the forklift truck’s forks unintentionally dropped, trapping the employee’s hand beneath the machine. Tragically, the worker later underwent surgery resulting in the amputation of two fingers.
The HSE investigation concluded that the lifting operation had not been properly planned or carried out safely.
Key Safety Reminders for Employers and Duty Holders
Lifting operations remain one of the higher-risk workplace activities across many industries including manufacturing, construction, warehousing, engineering, and maintenance.
This case serves as an important reminder that you should:
Ensure Proper Planning of Lifting Operations
All lifting activities should be:
- Properly planned by a competent person
- Appropriately supervised
- Carried out in a safe manner
This applies not only to cranes and specialist lifting equipment but also forklift-assisted lifting activities.
Avoid Working Beneath Suspended Loads
Where reasonably practicable, employees should never place themselves beneath suspended loads.
If this cannot be avoided, additional control measures covered through the assessment process and safe systems of work must be implemented to minimise risk, including:
- Ensuring loads are stable and secure
- Establishing exclusion zones
- Using suitable lifting accessories and equipment
- Maintaining clear communication throughout the task
- Ensuring all personnel understand their roles and responsibilities
Review Risk Assessments and Training
Employers should regularly review:
- Lifting operation risk assessments
- Method statements and safe systems of work
- Competency and training of operators and those involved in lifting activities
- Inspection and maintenance records for lifting equipment and accessories
Even experienced employees remain at risk where systems and planning are inadequate.
Take Extra Consideration for Non-Routine Lifts
Forklift trucks are commonly used for lifting activities outside routine pallet handling. However, non-standard lifting tasks can introduce significant additional hazards.
Before undertaking any non-routine lift, consideration should be given to:
- Load weight and stability
- Ground conditions
- Equipment suitability
- Attachment compatibility
- Visibility and communication
- Emergency arrangements
Enforcement Action and Legal Duties
The company pleaded guilty to breaching Regulation 8(1) of the Lifting Operations and Lifting Equipment Regulations 1998 and was ordered to pay prosecution costs and a victim surcharge.
The HSE reiterated that many serious and fatal incidents continue to occur each year due to poorly planned lifting operations and confirmed it will continue taking enforcement action where duty holders fail to protect workers adequately.
Final Thoughts
Incidents involving lifting operations can have devastating and permanent consequences within seconds.
Effective planning, supervision, communication, and safe systems of work are essential to reducing risk and protecting employees involved in lifting activities.
This case provides a timely reminder for organisations to review their current lifting procedures, training, and controls to ensure they remain suitable and effective.