Galvanising Firm Fined £500,000 After Worker Injured by Molten Zinc

A 33-year-old worker sustained life-changing injuries when a three-tonne steel beam fell into a bath of molten zinc. The resulting wave of liquid metal covered the employee, leading to an 11-day stay in intensive care and 13 separate surgical procedures. The incident highlights the extreme hazards present in galvanising and metal treatment facilities.

An investigation by the Health and Safety Executive (HSE) found that the company failed to ensure the safety of its workers during high-risk lifting and dipping operations. The lack of adequate physical barriers or automated systems meant that employees were positioned too close to the hazardous molten bath when the heavy load fell.

For procurement and safety managers, this case serves as a critical reminder of the importance of robust risk assessments and the implementation of the hierarchy of controls. Beyond standard high-temperature PPE, industrial sites must prioritise engineering controls such as splash guards, remote lifting systems, and exclusion zones to prevent direct contact with hazardous substances.

Source: HSE