Company Fined After Scald Injuries During Steam Pipe Maintenance

Brief Summary

Two workers were scalded while replacing a gasket on steam pipework after the employer failed to risk assess the task or document a safe system of work; isolations and lock off procedures were not used and work at height and supervision controls were inadequate. The prosecution and fine underline the need to plan isolation work and manage work at height properly.

What Was The Incident?

Two men were replacing a leaking gasket on an isolation valve in the boiler room of a manufacturing site. They worked from a gantry that did not give direct access to the valve and stepped onto the top of the boiler to reach the part. When the gasket was removed hot water escaped and both men were splashed and suffered scald injuries. One worker sustained around 4 to 5 percent subdermal burns and the other sustained about nine percent subdermal and second degree burns. The HSE investigation found the employer had not risk assessed the task or prepared a documented safe system of work, did not apply suitable isolation and lock off procedures, carried out work at height without sufficient fall prevention measures and lacked adequate supervision and monitoring to make sure required processes were followed.

What Was The Outcome?

The employer pleaded guilty to breaching Section 2 of the Health and Safety at Work etc. Act 1974 and was fined 594,000. The company was ordered to pay 5,834 in prosecution costs, a 2,000 victim surcharge and 6,000 in compensation to the injured employee. All sums are to be paid by 4 January 2027.

Key Points To Consider

Task risk assessments and documentation. Verify each maintenance job has a recorded risk assessment method statement and any required permits and isolation certificates before work starts and record the safe system of work.

Isolation and lock off procedures. Check that isolation plans and lock off procedures are suitable for the equipment involved and that isolations are proved and signed off before any intrusive work on pressurised pipework.

Access equipment supervision and fall prevention. Confirm that access equipment provides safe reach to the task so workers do not stand on plant; verify competent supervision monitoring and appropriate measures to prevent falls from height are in place.

HSE Prosecution Link