Michael Densmore, from Halewood, Merseyside, died as a result of complications from the wound he suffered after his right foot slipped into a container containing a liquid chemical of calcium hydroxide – known as ‘milk of lime’ – causing chemical and thermal burns.
The 37-year-old father of four was one of several scaffolders employed by Altrad NSG to erect scaffolding at Tata’s Lostock Hall site.
On November 30, 2016, during this work, Densmore stepped over a trough containing milk of lime – which had been heated to approximately 90 degrees Celsius. His right foot slipped on a loosened lid covering the trough, causing him to suffer chemical and thermal burns to his foot and ankle.
He was flown to the burn unit at Whiston Hospital where he received specialist treatment and underwent surgery on December 8 and was discharged just over a week later. But on January 3, 2017, while at home, he suffered a hemorrhage in his right foot and was taken to hospital after a 999 call, but tragically died.
The HSE investigation found that there was no permit for hazardous work in a living chemicals factory. There had been little proper consideration of the risks involved by those responsible for ensuring the safety of staff.
As far as the scaffolding team is concerned, there was no clear plan to address these risks. Densmore had received only a brief introduction when he started working at the site a few months earlier. Crucially, he had not been warned that chemicals would flow through the factory and that the trough lids had not been properly closed.
Tata employees were seen working on or near the troughs and there were no visible warning signs in place.
It also found that there had been previous prosecutions against Tata Chemicals Europe relating to health and safety failings at Lostock Hall and nearby Winnington Lane.
Tata Chemicals Europe Limited of Northwich, Cheshire pleaded guilty to safety breaches and was fined £1.125 million and ordered to pay £60,603.54 in costs at Chester Crown Court on Thursday.
After the case, HSE Inspector Matt Lea said: “This tragic death could have been prevented if Michael Densmore and his colleagues had been managed under a robust work permit system for working in a live chemical plant that contained corrosive chemicals heated almost to the point of . boiling point.
“Michael should not have been put in this unsafe working situation and should have been warned of the dangers of stepping over the troughs and that they were still in operation.
“Businesses should learn from this incident if they have staff or contractors working in a similar environment and be aware that HSE will not hesitate to take appropriate enforcement action against those who fall below the required standards.”
In a statement from his family, Densmore was described as “a loving and wonderful role model” to his sons and two nieces.
“Our lives fell apart and have not been the same since that terrible day,” they said. “No one should have to lose someone they love due to an accident at work.
“A mother should never have to resuscitate her own son, and a partner should never tell her children that their father won’t be coming home.
“Michael has missed so many life events over the past seven years, including missing his nieces having their own babies, his eldest son giving him a grandson, his youngest boys’ communions, to name a few.
“What hurts us most is the fact that he will never be able to achieve all the plans he had for life, including marrying his Helen.
“The trauma we have all suffered as a family cannot really be put into words. We were once a small, happy, close-knit family, all living life to the fullest, with Michael as the leader, and now we get through almost every day.”