The bricks were almost all broken in half. The whole load piled into the bulkhead, snapping it off and pushing it into the cab. The plastic tube carrier snapped off and its contents went flying forwards, with potentially fatal consequences.

Worse was to come when we watched a film of the crash in slow-motion.

The load had pushed itself forward into the back of the driver’s seat. As the driver was restrained from going forwards by the seatbelt, it is likely he would have suffered serious injury.

In comparison, the second test seemed rather tame but was carried out to show how much safer things could be when loads are restrained properly.

This van was fitted with a racking system provided by Sortimo.

The racking was filled with packages of various sizes and some odd items, such as traffic cones, were strapped in with proper restraining leashes.

When we examined the vehicle after the crash, it had hardly altered. The racking was slightly bent, but even the packets stayed put.

36,000 injuries – the heavy cost of manual handling

Although there is no legal limit to the weight a person should be expected to lift at work, the consensus is it should not be more than 25kg.

Official HSE statistics for the year ending April 2011 show that more than 36,000 workers suffered a reportable injury that involved  manual handling.

Almost 28% of these injuries were directly linked to lifting or putting down items while a further 19% were related to unspecified handling, lifting or carrying.

One answer to the lifting problem is to fit a small hoist, such as those provided by Penny Hydraulics.

A spokesman told Fleet Van: “Employers should do more to reduce or remove the risks associated with manual handling in the workplace.

“The best solution is to remove the need for manual handling but if this is not possible, a suitable mechanical aid such as a goods lift or vehicle-mounted crane or platform lift is often the next best option.

It remains the employer’s duty to simplify their handling processes or provide employees with the tools and equipment to do their work more safely, efficiently and productively.”

Loading tips for fleet managers

• Write company guidelines and procedures on how to load and store equipment and tools safely.
• Carry out regular checks to ensure drivers are aware of and following them.
• Ensure vehicles are adequately specified to carry the intended load, equipment or tools.
• Provide appropriate training for drivers so that they are aware of the hazards in a crash and know how to load and store equipment.
• Provide appropriate restraints for loads, tools and equipment.
• Fit vehicles with storage and racking systems that have been assessed for crash-worthiness.
• Carry out risk assessments of the vehicle’s equipment and cargo, vans and fleet operations in terms of their crash safety.
• Document the risks and any actions taken to mitigate them. Review and assess regularly.
• Allow time for checks on tie-down points, lashing and netting systems to ensure they are not damaged and worn.
• Be open to drivers’ concerns and advice on modifications to vehicles and load security.
• Seek professional advice if you have any concerns or uncertainties over the crash safety of your vehicles.