TWO men tragically died after their stairlifts manufactured by a Steeton company snapped in a "catastrophic failure", an inquest has heard.
The men, both aged 79, died in separate incidents three months apart in 2013.
George Bathmaker died of a spinal injury and cardiac arrest in September of that year, consistent with falling down the stairs, the joint inquest at Westminster Coroner's Court heard.
In July 2013, James Bell died of a severe head and chest injury after falling down 13 steps inside his home in Ramsgate, Kent.
Mr Bathmaker had been using an Acorn Superglide 120, supplied by Acorn Stairlifts, at his home in Mitcham, Surrey.
Recalling his fall, the retired bus driver's wife, Valerie, said in a statement read out by coroner Dr Shirley Radcliffe: "I heard the most awful clatter and bang."
She added that she would never forget the "horrendous" noise.
"He was a gentle soul and it hurts me to think he had a possibly violent end to his life," she said in her statement.
A statement from Mr Bell's partner, Ann Stubborfield, said she recalled finding him at the bottom of the stairs.
"There was blood pouring from his mouth and nose," she said.
He later died at King's College Hospital.
The inquest heard from James Rennie, a forensic services expert who spoke about his concerns regarding the design of the stairlifts.
Sam Harmel, representing the Bathmakers, put it to Mr Rennie that his report said the stairlifts were of "substandard welds and flawed design", to which Mr Rennie agreed.
Mr Rennie added: "Perhaps I could have said inadequate."
But under cross-examination Mr Rennie accepted that further rigorous testing had shown the design to be "fit for purpose".
He added that he personally would have made changes to the design, by using continuous welds - a term used to describe the fusion of two pieces of metal. He would also have made sure they were double-sided and with increased depth.
Karl Evans, a chartered engineer from independent experts Burgoynes, said the original design was adequate.
He said: "The original contemporaneous design was fit for purpose.
"If the weld was properly executed to the design specification there would not have been a failure."
Alexandra Tampakopoulos, representing Acorn, said these had been the only two reported incidents from 120,000 stairlifts over a four-year period.
Following the deaths, Acorn Stairlifts issued a recall in December that year and recovered more than 200 components, which the company replaced.
Of those, 38 were found to have weld defects, but under rigorous testing simulating daily use none suffered cracks or similar issues to those experienced by the stairlifts used by the men who died.
William Waddell, for Acorn, told the hearing that the news of a second death prompted a major recall "there and then" in an effort to contact thousands of customers and provide replacements.
A total of 43,556 stairlifts were sold directly by Acorn, with a further 14,054 sold through dealers.
"Everyone now has been contacted in some way," he said, detailing phone calls the company made, letters they sent and visits to customers' homes.
"We have exhausted every avenue to try and find the stairlifts," he added.
Mr Waddell told the inquest: "To date 29,300 seat posts have been replaced in the UK."
Discussing the firm's "rectification programme", Caroline Killbride of West Yorkshire Trading Standards service, said it had "acted appropriately in line with their obligations" and had "sufficient recall procedures".
Recording verdicts of accidental death, Dr Radcliffe said: "Investigations revealed there had been a catastrophic failure of a welding joint between the tubular seat post and the attachment plate."
The coroner said this occurred as a result of "inadequate welding at the time of manufacture of the seat post".
A spokeswoman for Acorn Stairlifts extended its deepest sympathies to the families of both men, saying it had taken full responsibility for the incidents, and acted to ensure they are not repeated.
She added: "We would like to reassure our customers that Acorn Stairlifts are safe for use and since these tragic deaths in 2013, there have been no further incidents."
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