Manufacturing Company Fined After Steam Pipework Scald Incident

Brief Summary

Two workers were scalded while replacing a gasket on steam pipework in a factory boiler room. The Health and Safety Executive found the employer had not carried out a suitable risk assessment or documented a safe system of work, failed to use isolation and lock off procedures, and allowed work at height without proper control or supervision. The case resulted in a substantial fine and costs.

What Was The Incident?

Two men were replacing a leaking gasket on an isolation valve in steam pipework above a boiler. They worked from a gantry that did not give proper access to the valve so both stepped off the gantry and worked on top of the boiler. When the gasket was removed hot water sprayed from the pipework and both were scalded. One man suffered four to five per cent subdermal burns and the other suffered nine per cent subdermal second degree burns. The investigating regulator found there was no documented safe system of work or suitable risk assessment for the task, isolation and lock off procedures were not used, work at height controls were insufficient, and supervision and monitoring were lacking.

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 594000 pounds, ordered to pay 5834 pounds in prosecution costs, a 2000 pound victim surcharge and 6000 pounds in compensation to the injured employee. The sentencing took place on 4 September 2026 and all sums were to be paid by 4 January 2027.

Key Points To Consider

Isolation and lock off procedures. Review written isolation and lock off arrangements for maintenance work, require certificates or permits that prove isolations are intact and confirm procedures are followed before intrusive tasks begin.

Task planning and safe systems of work. Require documented risk assessments and method statements for maintenance tasks, and verify that planned access gives a safe working position so workers do not need to step onto plant or boiler surfaces.

Supervision and controls for working at height. Check that supervisors are competent, that the right equipment is used for work at height, and that monitoring is carried out to make sure fall prevention and other controls are enforced.

HSE Prosecution Link