A chemical company which facilitates the chemical fuels and feed industries was fined after a worker experienced serious injuries while at work.
A faulty steam hose and poor manual handling resulted in burns and scarring of an employee. Cumbersome machinery with lacklustre safety mechanisms were regularly used by the company, and inevitably caused serious injuries. The injuries led to a costly £100,000 claim as well as an order for immediate implementation of control measures.
A critical issue; upon HSE inspection, it was found that on-site engineering teams had no understanding of the risks involved at the plant. The company also had no records relating to the maintenance of the machinery.
This case study is a prime example of the importance of teams understanding the importance of equipment maintenance, as well as the necessity for risk training. Many of the issues involved in this case could have been avoided through a health and safety inspection from Sentient. Sentient are a risk management HR and health & safety outsourcing service able to provide guidance and feedback to companies. As partners of Romero Insurance, they offer visitations as well as documentation and training.
The Incident
23-yearoold worker at a chemical company based in Newarthill, near Motherwell in Scotland, had been instructed to clean a water tank. The water tank was a component of the company’s rendering plant which processes animal waste. This was during a nightshift, and the worker had been instructed to clean the difficult areas of the factory, including areas of the floor, walls and the vickery.
In a two-man team, they used a steam hose which was heavy and cumbersome. However after a break the 23-year-old continued the work on his own. He used a cherry-picker vehicle, attached the steam hose to it, and would raise the basket to the required height. The nuzzle spun round and steam began flowing directly at him. The worker then lowered the basket, protecting his face from the hot water, and went to cool his injuries. He was taken to the hospital to care for several parts of his body which were burned and scarred.
The Investigation
Upon investigation, many inconsistencies and overlooked obligations were evidenced, showing the company to be at grievous fault.
The HSE’s investigation discovered that the nozzle fitted to the steam hose was unsafe. It was not properly insulated and was not fitted with a mechanism to start or stop the flow of water. Also the equipment which mixed the hot water supply for cleaning purposes was not in good repair. It was evidenced that supervisors had knowledge that the steam hose was faulty and yet no action was taken to prevent the issue, or even investigate the issue.
HSE inspectors questioned the teams at the premises. They had no clear understanding of the risks or how to mitigate against the risks. Control procedures were not being followed and there were no records associated with maintenance of the steam hose or its nozzle.
The Outcome
Ultimately, due to grievous errors on the part of the business, lack of records, and the outcome of significant lifelong injuries to a worker, The Scottish chemical company was fined £100,000 in August 2025. The company had pled guilty to breaching the Health and Safety at Work Act and were require to perform immediate remedial measures.
The HSE inspector called the incident entirely preventable. The company lacked appropriate risk assessments or method statements, and has not undertaken sufficient training or supervision. Both the maintenance team who installed the valve and the teams who used the steam hose were found at fault and to be unsafe. Simple control measure were not followed or even preexisting, and this catalogue of failures resulted in the scarring of a worker; injuries which could have been much worse.
Health & Safety and Risk Management Guidance for Businesses with Sentient
This outcome is an example of how poor control measures and risk management can result in the injury of workers and a significant fine. Yet, even without an event occurring, HSE inspection can still reveal the poor safety management of your business or facility. Ultimately, business should work to have effective health and safety and risk management procedures in place at all times.
HSE inspections are serious and can happen at any time to any business. Company need to be able to identify risk and continue effective maintenance. It’s the responsibility of a business’s Health and Safety Officer to ensure colleagues are adhering to the company’s health and safety policy, and to notice any changes that need to be made on the premises to reduce risk.
For more advice on your Health & Safety and to access our risk management services, contact our partner Sentient. Avoid scenarios such as the above by adopting Sentient’s services and receive a beneficial visitation. Contact Sentient and talk to our team for advice, and to see Sentient’s health and safety material.
