Workers Scalded During Steam Pipe Maintenance

Brief Summary

Two people were scalded during maintenance on steam pipework at a food manufacturing site when a leaking gasket was removed without adequate isolation, documented safe systems of work or suitable measures for working at height. The case shows failures in basic planning, isolation and supervision that health and safety professionals should check in their own maintenance controls.

What Was The Incident?

Two men were replacing a leaking gasket in an isolation valve on steam pipework in a boiler room. They worked from a gantry that did not reach the specific valve so both stepped onto the boiler to access the part. When the gasket was removed hot water was released and both were splashed, suffering scald injuries. One person received four to five percent subdermal burns and the other nine percent subdermal second degree burns. The investigation found the task was not risk assessed, no documented safe system of work was in place, isolations and lock off procedures were not used and the work at height lacked sufficient measures. There was also inadequate supervision and monitoring to make sure expected 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. The company was fined 594,000 and ordered to pay prosecution costs of 5,834, a victim surcharge of 2,000 and 6,000 compensation to an injured employee. The court hearing was on 4 September 2026 and all sums are to be paid by 4 January 2027. The Health and Safety Executive brought the prosecution.

Key Points To Consider

Plan isolations and document the work. Review permit to work arrangements, confirm that risk assessments and method statements are in place and keep isolation and lock off records; require proof of isolation before any intrusive work proceeds.

Provide safe access for maintenance at height. Check that access equipment reaches the exact location so people do not have to step off a gantry or work on unsupported surfaces; specify the correct equipment and describe acceptable work positions in the method statement.

Strengthen supervision and compliance checks. Set and record supervisory responsibilities, monitor that lock off and isolation procedures are followed and carry out spot checks during maintenance to verify procedures are enforced.

HSE Prosecution Link