Transforming rail freight safety

A leading UK rail freight operator experienced a serious safety incident when an employee’s hand was caught in the heavy iron door of a shunter carriage, resulting in the loss of a finger.

At the time, the worker was wearing standard leather driver gloves, which offered no impact or cut protection. Following the incident, the company’s PPE distributor, Bodyguard, contacted uvex to identify a more effective hand protection solution.

Bodyguard had previously received uvex training on the HexArmor glove range, including details of its performance in ASTM impact testing, which exceeds the EN standard, making it a strong candidate for high-risk applications.

The primary objective was to prevent similar incidents while demonstrating a proactive approach to the Health and Safety Executive (HSE).

The shunter carriage doors in use were heavy-duty and prone to hinge drop over time, requiring forceful slamming to close. This created a consistent risk of crush injuries.
Key challenges included:

• Lack of back-of-hand impact protection in existing gloves.
• Need for cut resistance, grip and dexterity.
• Seasonal variation such as breathable gloves for summer, more insulated options for the winter.

uvex began with a site audit to observe working practices and identify glove requirements for different tasks. The aim was to standardise to a single protective solution where possible. Two glove types were initially trialled:

• Rig Lizard 2021X – TPX palm, similar to existing leather gloves but with added impact protection.
• Thin Lizzie 7101 – sandy nitrile fully coated, offering superior grip together with impact resistance.

Feedback favoured the sandy nitrile gloves for grip and protection, but concerns were raised over breathability in warmer months. uvex responded by introducing the HexArmor Rig Lizard 2090X, a breathable option with the same protection levels.

Alongside PPE changes, engineering controls were implemented, including adding door blocks to slow closing speed. This ensured PPE remained the last line of defence rather than the only measure.

The gloves were approved by the company’s health and safety team and added to its digital PPE wardrobe system supplied via Bodyguard Workwear, enabling employees to order replacements via an app. On average, each worker uses around 10 pairs per year, with buffer stock held on-site.

• Improved safety: Gloves now provide both impact and cut protection, significantly reducing injury risk.
• Extended lifespan: Gloves last 4 - 5 weeks compared to 3 - 5 days for the old leather models.
• Compliance and reassurance: The comprehensive solution, including engineering controls, was praised by the company’s insurance inspector.
• Prepared for future upgrades: The company plans to transition to the next-generation Rig Lizard 2090X with updated back-of-hand design.

The original incident carried an estimated cost of £120,000. By implementing a durable, protective glove solution alongside engineering controls, the operator has reduced the likelihood of repeat incidents and reinforced its commitment to worker safety.