Large Fine After Steam Scald Injuries In Factory

Brief Summary

Two workers were scalded while replacing a leaking gasket on an isolation valve on steam pipework. The employer had not risk assessed the task, did not document a safe system of work, and failed to apply or verify isolation and lock off procedures. The case illustrates the need to plan intrusive work and to prove control measures before starting work.

What Was The Incident?

Two men were replacing a leaking gasket on an isolation valve in a boiler room. The intended access from a gantry did not reach the valve so both stepped off the gantry and worked on top of the boiler. When the gasket was removed hot water from the pipework splashed both men. One sustained about 4 to 5 percent subdermal burns and the other about 9 percent subdermal second degree burns. The investigation found no suitable risk assessment or written safe system of work for the task, isolations and lock off procedures were not used or proved, work at height controls were inadequate 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 and was fined £594,000. The employer was ordered to pay £5,834 in prosecution costs, a £2,000 victim surcharge and £6,000 in compensation to the injured employee. All sums are to be paid by 4 January 2027.

Key Points To Consider

Risk assess and record the task. Prepare and approve a written risk assessment and a safe system of work before intrusive maintenance. Include method statements, permits and isolation certificates and make sure the documentation is available to the team and supervising staff.

Prove isolation and lock off before work. Require isolation certificates and a test to prove the integrity of isolations before any intrusive work on pressurised systems. Use physical lock off devices and a clear handover process so workers can confirm the energy source is isolated.

Plan access and supervision for work at height. Confirm safe access and the right equipment for working at height so people do not need to step onto unsafe surfaces. Assign competent supervision, record checks and monitor work to make sure procedures are followed.

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