A life changing injury in the blink of an eye changed everything for Carl Harris
A Teesside bricklayer turned inventor transformed his life after nearly losing his home and family in the wake of a devastating injury. Carl Harris suffered the debilitating leg injury on site in 2018 after almost three decades in his trade.
It left him unable to work, with an addiction to painkillers and his mental health suffered – but after overcoming a torrid time in the aftermath of the accident he had a revolutionary idea.
Carl is now managing director of Harris Brick Safety Systems and inventor of The Brick Bud – a unique wall bracing safety system that boosts safety on building sites. His invention is going global and he has praised a scheme backing Teesside entrepreneurs for providing the crucial “turning point” for his venture to grow.
He said of the day his life changed: “The wind had picked up – I built the wall to the guidelines and braced it with timber, with methods which continue to this day, and started working on another part of the wall.
“I’d left my trowel on the other side, went to go and get it and it came down. It pinned my left leg to the floor causing lifechanging injuries.”
It was a tough journey for Carl over the course of the next two years, a time that saw him nearly lose his car, his home and his family.
In the aftermath, he said he “was addicted to painkillers”, adding: “I did try to go back into the bricklaying game, but I lasted about a week – I had to think about changing my career.”
Now 49, Carl went to Brackenhoe School in Middlesbrough, leaving in 1991. He learned bricklaying as a trade, serving his apprenticeship and then working in the trade for 27 years, working his way up to senior site manager.
He recalled: “The health and safety has moved on. Years ago, we were allowed to start a Stihl saw with no water suppression or masks on. It’s changed a hell of a lot.”
Carl studied and secured health and safety qualifications but struggled to find work. After completing his Site Management Safety Training Scheme (SMSTS), he became a senior site manager with major housebuilders.
The pandemic left him once again struggling to pay the bills – before he finally decided to fuel the idea he’d held onto for years. It was one which would put a stop to anyone ever facing the same ordeal he’d stared down.
He added: “Covid hit and I had a lot of time on my hands. I’d always had my idea of a Brick Bud but I’d put it on the backburner because I was very busy.
“During Covid, I didn’t get any furlough and I put some drawings together and approached a patent attorney. He then gave me the good news that there was nothing out there like this on the market.”
Carl’s patented wall-bracing system is a robust, light, versatile and adaptable A-Frame which folds out and fixes to the ground. It will hold a wall up to just under hurricane-force winds at 73mph.
“It will reduce accidents and near misses – as well as possible fatalities,” he explained.
“It will reduce carbon footprints, help sites reduce monetary losses, and it will help sites adhere to their programmes.
“It keeps sites safe and compliant. It’s a safe system of work. It’s so simple, easy to install – it takes 90 seconds.”
Support through the separate Innovation Net Zero scheme, funded by Innovate UK, helped him leave his job and put 100% of his time and effort into the Brick Bud system.
With more devices developed and made, he approached major housebuilders with his invention and began working with Further Education colleges to train students on the device.
Carl says the “real turning point” was being approached by Middlesbrough innovation consultancy Alt Labs.
It runs Tees Valley Labs, a programme funded by the Tees Valley Mayor and Combined Authority that was designed to fast-track the success of the region’s entrepreneurs, start-ups and scale-ups with structured support for firm founders.
The Forge at Tees Valley Labs is a 12-week accelerator delivered by Alt Labs to help companies primed to scale up and attract significant investment.
Carl joined the Forge and says the mentorship he received helped him focus on what he wanted from his venture and the Brick Bud.
He said: “I met some outstanding people – friends for life. We had the opportunity to put a shopping list together to put together what we needed for our business to grow.
“I was lucky enough to receive help with some of my patent costs – my attorneys, litigation costs, stock on the ground and a new website. It’s opened a hell of a lot of doors.
“We were already speaking with a contact in Australia with a contract going back and forth.
“The programme helped us look at the contracts – and spotted some things which definitely needed sorting.
“Without them, there may well not be a Harris Brick Safety Systems today. We’re now finalising contracts.”
A fireside chat during the programme changed Carl’s mind when it came to the company’s future and he now wants to leave it to his son.
Carl said: “I’d already put on the board that I wanted my exit strategy in a year – and after that chat, I changed it straight away. It really opened my eyes.”
Tees Valley Labs is funded by the UK Government through the UK Shared Prosperity Fund.
Tees Valley Mayor Ben Houchen said: “Carl shows the grit and determination we’re famous for here on Teesside. He’s taken a tough situation, turned it into a world-class invention and is now flying the flag for our region. Tees Valley Labs is giving brilliant entrepreneurs like Carl the backing they need to grow, succeed and create jobs.”
Middlesbrough Mayor Chris Cooke, TVCA Cabinet Member for Inward Investment, added: “Carl’s story is a true Middlesbrough and Teesside success born of a tough situation, and I’m delighted Tees Valley Labs has played its part in his rise.
“His message of safety, and how he’s contributing to the whole industry on a national and international scale, are inspiring.
“We know there are lots of talented traders and entrepreneurs in our region who’d benefit from the brilliant helping hand Tees Valley Labs can provide – and I’d strongly urge them to get in touch with the team and grasp the help we can offer.”
Find more about booking a place on Tees Valley Labs here.
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