Channel Tunnel Operator Fined £2.25m After Worker Suffers Serious Injuries in Equipment Failure

The company responsible for the Channel Tunnel has been fined £2.25 million following a serious incident in which a heavy lighting unit fell and caused life-altering injuries to a worker.

The accident took place on 5 April 2018 at Eurotunnel’s Folkestone terminal, where a team was carrying out routine maintenance on an 18-metre lighting mast. During the work, a 115kg lighting carriage being raised up the mast suddenly fell after the supporting cables snapped, striking an engineering surveyor positioned below.

The carriage had been lifted using a winch operated by a power drill fitted with a torque limiter, designed to prevent excessive force. However, the limiter malfunctioned, placing too much strain on the cables and causing them to fail.

Eurotunnel, prosecuted under the name Channel Tunnel Group, admitted breaches of health and safety regulations and was sentenced on 10 April.

Prosecutor Gordon Menzies told the court that established safety standards for such equipment had been in place for decades. He said the company lacked proper systems to ensure the correct tools were used and had not implemented a safe plan for the task, despite a risk assessment being completed by contractors.

He described the incident as “an accident waiting to happen”, highlighting that an alternative manual lifting mechanism had been lost and that unsuitable equipment was used instead. Evidence also showed debris, including bird nesting material, present at the top of the mast.

The injured worker suffered multiple fractures and a head wound, requiring intensive care for several days and a lengthy hospital stay. In a statement, he described ongoing daily pain, limited movement, and psychological trauma, including recurring nightmares.

He said the injuries had drastically changed his life, affecting his relationships and leaving him struggling with even simple tasks. Once active, he now finds it difficult to carry out everyday activities and described his situation as repetitive and demoralising.

In its defence, Eurotunnel said it had accepted responsibility early and fully cooperated with investigators. The company stated that safety measures were quickly introduced after the incident, including fencing off similar masts and removing the lighting units within three months.

Defence counsel John Cooper KC said the reason for the torque limiter failure remained unclear, noting it had functioned correctly earlier that day. He also maintained that the masts themselves were in good condition and that workers sometimes needed to be close to the equipment to ensure safe operation.

The defence also pointed to the manufacturer, Abacus, suggesting there had been no warning of potential design issues and that clearer guidance on maintenance procedures should have been provided.

Following the case, HM Chief Inspector of Railways Richard Hines criticised the failures, describing the incident as the result of multiple preventable errors in planning and maintenance. He expressed concern that workers had operated equipment without proper training or a safe system of work in place.

The court will determine additional costs related to the case at a later date.