Scald Injuries During Steam Pipe Maintenance At Food Factory

Brief Summary

Two workers suffered scald injuries while replacing a leaking gasket on steam pipework at a food factory. The employer failed to risk assess the task, to document a safe system of work, to apply proper isolation and lock off procedures and to provide safe access and supervision. The case is a reminder that planned job documentation and proved isolations are essential for intrusive work on pressure systems.

What Was The Incident?

The injured workers 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 and so stepped onto the boiler to reach the component. When the gasket was removed hot water was released and both workers were splashed and scalded. One worker sustained burns affecting about 4 to 5 percent of the body surface described as subdermal. The other suffered burns to about 9 percent of the body surface described as subdermal second degree burns. The investigating regulator found the employer had not carried out a suitable risk assessment, had not prepared a documented safe system of work, did not use suitable isolation and lock off procedures, allowed intrusive work without proving isolations and carried out work at height without adequate measures or supervision and monitoring.

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 was ordered to pay 5,834 in costs, a victim surcharge of 2,000 and was ordered to pay 6,000 in compensation to an injured worker. The fine and financial orders were handed down on 4 September 2026 and all sums were to be paid by 4 January 2027. The prosecution was brought by the regulator.

Key Points To Consider

Risk assessment and documented safe work. Confirm that every intrusive maintenance task has a written risk assessment, method statement and permit where needed, and that these documents are authorised before work starts.

Isolation and lock off practice. Verify isolation arrangements for pressure systems and prove the integrity of isolations before any opening work, with clear lock off measures and checks recorded.

Access supervision and working at height. Provide suitable access so workers do not need to leave safe platforms, use the right equipment for work at height and apply competent supervision and monitoring to confirm procedures are followed.

HSE Prosecution Link