Accidents clearly cost money due to injuries, damaged equipment, and wasted products. The HSE estimates that occupational injuries and illnesses cost the UK between £20 and £30 billion each year, considering the total costs to individuals, employers, and society. Official inquiries often determine the costs of large-scale accidents involving significant loss of life or major property damage from fires and explosions.
The financial cost of accidents is evident in major incidents. The BP Texas City fire and explosion in 2005 cost over $21 million in fines, $2 billion in civil claims, and $1 billion to reinstate the site. The Buncefield oil refinery fire in 2005 is the most expensive accident in UK history, with a total cost exceeding £1 billion, including £9.5 million in fines.
Smaller accidents are harder to cost since few companies have systems to quantify them.
HSE Guidance from 2002, “Reduce Risks – Cut Costs” (INDG355), identified three methods for quickly estimating uninsured accident costs:
- Uninsured costs are about 10 times the insurance premiums paid.
- Uninsured losses in smaller firms add up to £315 per employee per year.
- The average uninsured cost of an accident causing work absence is approximately £2100.
Every business and incident differs, so the only accurate way to determine costs is to measure them.
HSE Guidance from “Reduce Risks – Cut Costs” (INDG355)
Direct and Indirect Costs
Direct costs are easily attributed to an incident, including:
- fines
- first aid
- sick pay
- medical treatment
- equipment repairs/replacement
- lost or damaged stock
- lost production time
- replacement staffing
Indirect costs can remain hidden and may not link to a single incident. Poor health and safety performance still incurs losses over time, including:
- time spent investigating incidents
- loss of goodwill
- loss of reputation
- low staff morale
- lost contracts
- higher recruitment costs
- increased insurance premiums
Insured and Uninsured Costs
Additional costs include those related to replacement labour, accident investigation time, downtime, and increased insurance premiums due to poor claims history.
If an accident causes an injury, the injured worker may claim personal injury compensation. Damages depend on factors like loss of faculty (e.g., sight or hearing), the injury’s permanence, and its impact on the claimant’s earning ability.
The financial cost of accidents can be likened to an iceberg: visible costs are covered by insurance, while hidden, uninsured costs below the surface are much greater.
Employers’ liability insurance covers some financial costs, but businesses still face costs such as:
- lost time
- sick pay
- fines
- retraining
- lawyer’s fees
- damage to stock/equipment
- loss of reputation
- lost contracts
These hidden costs can significantly impact a business, emphasising the importance of robust health and safety practices.


