Manufacturing Company Fined After Steam Pipework Scalds

Brief Summary

Two workers suffered scald injuries while replacing a gasket on steam pipework in a factory boiler room. The HSE found the employer had not risk assessed the task or documented a safe system of work, had not used suitable isolation and lock off procedures and had inadequate controls for working at height and supervision. The case resulted in a large fine and costs and underlines the need to plan intrusive work and confirm isolations before starting.

What Was The Incident?

Two men were replacing a leaking gasket in an isolation valve on steam pipework in a factory boiler room. They worked from a gantry but could not reach the valve, so both stepped off the gantry and worked on top of the boiler. When the gasket was removed they were splashed with hot water from the pipework. One worker suffered 4 to 5 per cent subdermal burns and the other suffered 9 per cent subdermal second degree burns. The HSE investigation identified multiple management failures including no documented risk assessment or safe system of work for the task, lack of suitable isolation and lock off procedures, inadequate measures to prevent a fall from height and insufficient supervision and monitoring of the work.

What Was The Outcome?

The employer pleaded guilty to breaching Section 2 of the Health and Safety at Work etc. Act 1974. The company was fined 594,000, ordered to pay 5,834 in prosecution costs, a ,000 victim surcharge and 6,000 compensation to the injured employee. Sentencing took place on 4 September 2026 and all sums are to be paid by 4 January 2027. The prosecution was brought by the Health and Safety Executive.

Key Points To Consider

Plan and document isolation work. Review and record risk assessments, method statements, permits and isolation certificates for any intrusive work on pressure systems and ensure a documented safe system of work exists before starting.

Confirm physical isolation before intrusive work. Require positive isolation and lock off for steam and hot fluid systems, prove the integrity of isolations and depressurisation before opening equipment and verify these steps in writing.

Control access and supervision for work at height. Ensure tasks that require working at height have suitable access and fall prevention measures, are carried out by competent people and are supervised and monitored to confirm procedures are followed.

HSE Prosecution Link