A 44-year-old Contractor was crushed to death while working at Tata steel’s Port Talbot steelworks. The fatal incident led to a prosecution, and in July 2025, the company was fined £1.5 million following an HSE investigation that uncovered serious safety failings.
On 25 September 2019 contractor Justin Day was fatally crushed while working at Tata steel’s Port Talbot steel works in south Wales. Mr Day a father of three had been called to investigate a hydraulic leak on a large conveyor system after maintenance work to replace a lift cylinder took place earlier in the day, and the system was in the process of being put back into service when a hydraulic leak was found. Although power was isolated to part of the system, other sections remained live, as he accessed the system from the level above, a sensor detected his presence and activated a moving beam in a live section which caused fatal crush injuries and resulted in his death at the scene.
The Health and Safety Executive (HSE) highlighted several failings in this case:
- Parts of the conveyor remained live during maintenance which led to Justin being crushed to death.
- Work was not managed properly, leaving confusion about which sections of the systems were safe.
- Simple, routine safety steps that should always be followed were not applied.
- Safety arrangements did not give contactors the same safeguards as direct employees.
- The Hazards of moving machinery are widely recognised, yet straightforward controls were not used.
Legal Outcome:
Tata Steel (UK) Ltd, of Grosvenor Place, London, pleaded guilty to breaching Sections 2(1) and 3(1) of the Health and Safety at Work etc. Act 1974. The company was fined £1.5 million and ordered to pay £26,318.67 in costs at Swansea Crown on 31st July 2025.
HSE Statement:
The Health and Safety Executive (HSE) investigated Justin’s death and brought a prosecution against Tata for what an inspector described as “basic” health and safety failures.
HSE inspector Gethyn Jones said: “Justin Day’s death could so easily have been prevented. A much-loved family man is not here because of failures in health and safety basics. Employers have a responsibility to make sure sufficient procedures are in place to protect workers – both employees and contractors – and that those procedures are understood and followed. The dangers of moving machinery are well known. Sufficient risk assessments must be carried out and access to dangerous areas must be properly guarded and controlled. This has been a long and thorough investigation, and we believe this is the right outcome. Justin’s death has had a devastating impact on his family, his friends, and the wider community. Our thoughts remain with them.”
Preventive Measures:
To prevent incidents like this, it is essential that machinery is fully shut down and isolated before any maintenance work begins. Clear systems must be in place so that workers know exactly when equipment is safe to access, with no chance of it starting unexpectedly. Proper guarding should also be fitted and checked regularly to make sure people cannot come into contact with dangerous moving parts.
Equally important is good planning and supervision. Work needs to be coordinated, with contractors and employees being given the same clear instructions and protections. Regular checks, open communication and simple but consistent procedures help ensure that everyone on site can carry out their jobs safely without being exposed to avoidable risks.