How risk assessments prevent workplace deaths

The vital importance of risk assessments in the workplace cannot be overstated, as demonstrated by heartbreaking incidents that highlight how neglecting this fundamental safety step can lead to devastating outcomes. In the UK, employers have a legal duty under the Health and Safety at Work etc. Act 1974 to ensure so far as is reasonably practicable, the health, safety and welfare of their employees. Yet, tragic cases continue to remind us that failing to conduct thorough risk assessments can result in loss of life.

A stark example is the case involving Ward Bros (Malton) Ltd. On 8 January 2019, 30-year-old yard hand Gary Lee James suffered fatal injuries while performing a “devanning” operation, unloading and dismantling heavy metal clothing frames from a shipping container at the company’s South Bank yard in Middlesbrough. Each frame weighed up to 120kg and during the process, several unsecured frames toppled, pinning Mr James against the container wall. He was rushed to James Cook University Hospital but sadly passed away three days later after suffering a cardiac arrest.

The Health and Safety Executive (HSE) investigation revealed critical failures: the company had not carried out a suitable and sufficient risk assessment for this unfamiliar task. Ward Bros had never undertaken devanning work before, yet employees were left to devise methods through “trial and error,” with inadequate supervision, poor communication and no proper securing of the frames. Concerns raised by workers about the safety of the process were not adequately addressed and the system of work was described as ad hoc and ultimately unsafe. In 2025, the company pleaded guilty to breaching Section 2(1) of the Health and Safety at Work etc. Act and was fined £250,000.

This incident powerfully illustrates the vital importance of risk assessments, they are not mere paperwork but life-saving tools that identify hazards, evaluate risks and implement controls before accidents occur.

Understanding the Risk Assessment Process

Conducting risk assessments is a systematic process that every employer must follow. Start by identifying hazards, anything with the potential to cause harm, such as heavy loads, unstable structures or confined spaces like shipping containers. Then, determine who might be harmed and how, evaluate the level of risk (considering likelihood and severity) and decide on control measures using the hierarchy of controls: eliminate, substitute, engineer, administrate or use personal protective equipment as a last resort.

In the Ward Bros case, a proper workplace risk assessment would have flagged the dangers of unsecured heavy frames, the lack of experience in devanning and the need for secure storage or tethering. Regular reviews are essential too, especially when introducing new tasks or equipment. The HSE emphasises that poorly planned work contributes to a significant proportion of serious and fatal accidents each year.

Training and Communication: Key Pillars of Safety

Even the best risk assessments fail without effective training and communication. Employees must receive adequate instruction on hazards and controls specific to their roles. In the tragic Ward Bros incident, staff lacked appropriate training for devanning and safety protocols were not clearly communicated or enforced.

Training should be practical, ongoing and include how to report concerns. Open communication fosters a culture where workers feel safe raising issues without fear of reprisal. Employers should document training records and ensure refresher sessions as needed.

Accountability and Supervision in the Workplace

Supervision plays a crucial role in translating risk assessments into action. Managers must monitor compliance, lead by example and intervene when unsafe practices emerge. In the Ward Bros prosecution, the lack of supervision left employees to their own devices, contributing directly to the fatality.

Building accountability means appointing competent persons to oversee safety, conducting regular audits and ensuring everyone from directors to operatives, understands their responsibilities. A positive safety culture values wellbeing over haste.

Preventing Future Incidents Through Effective Risk Assessments

The vital importance of risk assessments lies in prevention. By proactively identifying and controlling risks, businesses can avoid tragedies like the one at Ward Bros. Simple steps such as securing loads, providing proper equipment and planning safe systems of work, save lives and reduce costly fines or reputational damage.

At AL23 Safety, we specialise in helping businesses across the UK develop tailored effective risk assessments that address unique workplace hazards. Our experienced consultants guide you through the process, from initial hazard identification to implementation and review, ensuring compliance with HSE standards and creating safer environments for your team.

Don’t wait for an incident to act. Prioritising conducting risk assessments demonstrates commitment to your employees’ safety and protects your business long-term. Contact AL23 Safety today for expert support in enhancing your health and safety management. Together, we can prevent avoidable tragedies and build workplaces where everyone returns home safely.