TARMAC have been fined £633,300 after an employee’s legs were crushed between one-tonne metal frames moving on a production line.

Richard Ogunleye was working for Tarmac Building Products Ltd at their block manufacturing plant in Linford, Essex, on 22 July 2022 when he entered a fenced area to manually clean and inspect the frames. The frames, which carry large blocks through the manufacturing process, move around the factory on a trackway.

Mr Ogunleye entered the fenced area through an interlocked gate which, when opened, was supposed to prevent frames from moving on that section of the track. As he was working on the stationary frame, another frame moved along the trackway into the section and struck him. His legs were crushed and pinned between the two frames.

Mr Ogunleye was trapped as the frames continued to move along the track, pushing him towards machinery on the next section. His right leg was broken and the other severely bruised as the frames moved over axles on the track. His colleague saw the incident from a distance and ran to help, pressing the emergency stop button in time to prevent further injury.

Mr Ogunleye spent two weeks in hospital, where a metal rod and screws were used to repair the injuries to his right leg. He was unable to return to work for more than a year and underwent extensive physiotherapy.

An investigation by the Health and Safety Executive (HSE) found that Tarmac Building Products Ltd failed to prevent access to dangerous parts of machinery, namely the moving frames on the track, or prevent the frames from moving when employees entered the danger zone. The interlocked gate which employees used to enter the frame cleaning area did not stop the power on the preceding sections of track and would, therefore, not prevent a frame from moving into this area when employees were working.

The HSE investigation also revealed that the company had failed to act following several near misses which had occurred on this section of the track in similar circumstances. The investigation also found that a risk assessment had been carried out by the company several years before the incident which identified ‘additional control measures required to reduce risk to an acceptable level’, but these were not put in place until after Mr Ogunleye was injured.

HSE guidance on safe use of work equipment states that employers must take effective measures to prevent access to dangerous parts of machinery. Employers should also investigate accidents and incidents of near misses as part of their monitoring process to identify why the existing risk control measures failed and what improvements or additional measures are needed.

Tarmac Building Products Ltd, who pleaded guilty to failing to discharge their duty under Section 2(1) of the Health and Safety at Work etc. Act 1974, were fined £633,300 and ordered to pay £5,583 in costs and a victim surcharge of £2,000 at Chelmsford Magistrates’ Court on 29 January 2026.

HSE inspector Connor Stowers said: ‘This was a serious and entirely avoidable incident which has had profound consequences for Mr Ogunleye, and were it not for the quick action of a fellow worker, the injuries he sustained could have been worse.

‘Employers need to ensure that dangerous machinery is guarded effectively, and this goes beyond the initial installation. Employers should frequently monitor how effective their measures are and make changes as needed. Monitoring arrangements should include properly investigating near misses and previous incidents.

‘In this case, had the previous near misses on the block production line at Tarmac Linford been fully investigated and sufficient action taken, this life-changing injury would never have occurred.’

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