Steam Pipe Maintenance Scalds Two Workers

Brief Summary

Two workers suffered scald injuries during maintenance on steam pipework after the employer failed to risk assess the task or document a safe system of work. The regulator found that isolations and lock off procedures were not used, access to the work was unsafe and supervision was inadequate. The case shows how basic failures in planning, isolation and supervision can lead to serious harm and significant enforcement action.

What Was The Incident?

Two men were replacing a leaking gasket in an isolation valve on steam pipework in a boiler room. They were working from a gantry that did not give direct access to the valve, so both stepped onto the top of the boiler to reach the part. When the gasket was removed they were splashed with hot water and suffered scald injuries. One worker had around 4 to 5 per cent subdermal burns and the other had around 9 per cent subdermal second degree burns. The regulator found there was no suitable risk assessment or documented safe system of work for the task, isolations and lock off were not applied or proved, access to the work was unsafe and measures to prevent falls from height were lacking, and supervision and monitoring of the work was inadequate.

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 prosecution costs of £5,834 in full, and a victim surcharge of £2,000. It was also ordered to pay £6,000 in compensation to an injured employee. The plea and penalties were entered at a magistrates court on 4 September 2026 and all sums are to be paid by 4 January 2027.

Key Points To Consider

Plan and document intrusive tasks. Review and issue written risk assessments, method statements, permits and isolation certificates before any intrusive work. Require that the integrity of isolations is proved and recorded before workers begin intrusive tasks.

Verify isolation and lock off. Make sure isolations and lock off measures are applied, tested and documented. Use permits to work and trained staff when hazardous energy such as steam is present.

Provide safe access and active supervision for work at height. Check that access equipment allows safe, direct reach to the specific part of the plant so workers do not need to step onto unsafe surfaces. Maintain supervision and monitoring to confirm procedures are followed and workers are competent.

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