Builder’s Merchant fined after timber pallet death

A major UK builder’s merchant has been fined £2.2 million following the death of a worker who was crushed by a three-tonne pallet of timber at a Suffolk sawmill.

Paul Coulson, 56, died on 22 May 2024 while working at Herringswell Sawmills near Bury St Edmunds, a site operated by Huws Gray Limited. He had been removing plastic wrapping from timber pallets prior to processing when the incident occurred.

Mr Coulson climbed inside the framework of a conveyor to access packaging. Unaware he was there, a colleague started the conveyor. The moving pallet struck Mr Coulson, and when the operative attempted to correct the fault by reversing and restarting the system, the load struck him a second time. He sustained fatal crush injuries and died at the scene.

An investigation by the Health and Safety Executive (HSE) found the company had previously identified unsafe access to the conveyor’s danger zone. Warning signage had been installed, but no effective measures were taken to prevent entry.

CCTV evidence showed workers entered the conveyor framework on 19 occasions in the weeks leading up to the incident.

Following Mr Coulson’s death, the company introduced additional controls, including physical guarding to prevent access, changes to the system of work so pallets are unwrapped before reaching the conveyor, and improved CCTV coverage to support safer operation.

HSE guidance highlights the risks associated with sawmilling, particularly where workers access dangerous parts of machinery to clear blockages or carry out adjustments. Employers are expected to implement robust control measures, such as fixed or close guarding, to prevent access during operation.

Huws Gray Limited pleaded guilty to breaching section 2(1) of the Health and Safety at Work Act. The company was fined £2.2 million and ordered to pay £9,929 in costs at Chelmsford Magistrates’ Court on 26 March 2026.

HSE inspector Joanne Williams said the case represented a ‘staggering failure’ to manage risk.

She said: “Our investigation found the company relied on instruction alone to control a serious hazard, rather than implementing appropriate safeguarding measures. This allowed workers to access a dangerous area, with tragic consequences.

“Had effective action been taken when the issue was first identified, this incident could have been prevented.”

For more information from the HSE, visit: HSE: Information about health and safety at work