A car mechanic was severely burned after an inspection pit he was standing in burst into flames, a court has heard.
CCTV footage of the incident shows Lee Roberts, 33, from Wigan, walking to the pit to remove fuel from underneath a van at Douglas Valley Breakers Ltd’s workshop on Blainscough Lane in Coppull on 22 July 2010. Seconds later, he is seen running out as fire engulfs the pit.
Multiple health and safety failings were discovered following a joint investigation by the HSE and Lancashire Fire and Rescue Service.
Leyland Magistrates’ Court heard that the car salvage firm regularly removes engine and gearbox oil, coolant, air conditioning liquid and fuel from old vehicles so they can be used for scrap.
The court heard that it was common practice for employees to puncture the fuel tank on vehicles to allow fuel to drain into an open container on the floor of the pit. An electric drill was also sometimes used to make a hole in the tank.
The investigation concluded that the most likely cause of the fire was that the drained fuel was set alight by a spark from the electric drill or an extension lead in the pit.
The fire grew rapidly due to the presence of petrol and was further fuelled by plastic car body parts and items of vehicle upholstery, spreading to involve the whole of the workshop.
Lancashire Fire and Rescue Service were called to bring the fire under control and, with the assistance of Lancashire Police, to ensure the safety of people nearby.
Mr Roberts sustained severe burns to his hands, legs and nose in the fire and has not been able to return to work since the incident.
The court was told that Douglas Valley Breakers should never have allowed fuel to be drained into inspection pits, where vapours could accumulate, and it should have made sure there were no ignition sources nearby, such as electrical equipment.
The company failed to ensure that the fuel was safely removed from the vehicle, despite having a piece of equipment that could be used to drain it into a sealed container.
HSE inspectors identified several other incidents of unsafe behaviour, including workers climbing up the outside of storage racks and riding on the forks of a telehandler to reach items high up on the racks.
Lancashire Fire and Rescue Service found the company did not have suitable fire detectors and alarms, failed to provide adequate fire safety training to staff and failed to have appropriate procedures in place for dealing with fires.
Douglas Valley Breakers Ltd, of Bradley Lane in Standish, near Wigan, pleaded guilty to breaching sections 5(1) and 6(1) of the Dangerous Substances and Explosive Atmospheres Regulations 2002, section 4(1) of the Work at Height Regulations 2005, and sections 13(1) (a) and 21(a) of the Regulatory Reform (Fire Safety) Order 2005.
On 31 October, the company was fined a total of £40,000 and ordered to pay £25,000 in costs.
Following the hearing, HSE inspector David Myrtle said: “Douglas Valley Breakers was guilty of several serious safety breaches. It failed to properly consider the risks its employees faced while removing fuel from vehicles, or to do anything about them.
“The company had the right equipment to do the job properly but instead it allowed workers to stand in a pit surrounded by fuel vapours where just one spark from electric equipment could start a fire.
“Sadly, our investigation found the company’s overall attitude to health and safety was poor to say the least.”
Assistant chief fire officer, David Russel said: “Lancashire Fire and Rescue Service is reminding all business owners and occupiers of their legal responsibility to protect their staff and customers against the risk of fire, and warning that we will take action against anyone found to be in breach of fire safety regulations.
“It is a legal requirement for places of work to have a Fire Risk Assessment and guidance is available on our website. If employers are unsure about their own ability to undertake a fire risk assessment within their premises they should seek advice from a competent person.”