WHS Case Study – Hot Coolant, Cold Reality: When Inexperience Meets Risk

A recent incident highlights the critical importance of effective supervision, risk assessment, and control measures when engaging young or inexperienced workers in higher-risk environments.

At a mechanical workshop, a 15-year-old work experience student was assigned a task involving the draining of a vehicle radiator. Prior to this, the vehicle had been running to assess overheating. The student was instructed to loosen a hose clamp to release pressure from the cooling system. At the time, the student was not under direct supervision, as the supervising mechanic was occupied with other work.

Before the placement commenced, the organisation had completed the required work experience documentation, which included commitments to:

• Identify hazards and control risks

• Nominate a supervisor responsible for the student

• Provide appropriate information, training, instruction, and supervision

Despite this, the student had not been adequately instructed on the correct process. Unaware that the system needed to be depressurised safely, the student accessed the underside of the vehicle and removed a hose clamp. This resulted in hot coolant being released under pressure, causing severe burns to the student’s face, hands, and chest, requiring multiple skin grafts. The incident also resulted in ongoing psychological harm.

Key Findings

The incident identified several critical failures. There was a clear lack of direct supervision during a hazardous task, alongside inadequate instruction and training, particularly given the worker’s age and inexperience. The organisation also failed to implement specific risk controls for work experience students and did not have a documented procedure addressing high-risk tasks involving hot systems.

The risk of injury from hot coolant was well known and foreseeable, and appropriate controls were readily available and reasonably practicable.

What Should Have Been in Place

To eliminate or minimise the risk, the organisation should have implemented a documented policy for managing work experience students, including restrictions on high-risk tasks. There should have been clear identification of specific hazards associated with mechanical work, particularly those involving hot systems. Direct supervision should have been maintained at all times when the student was performing tasks, supported by practical instruction and demonstration before any work was undertaken.

Regulatory Outcome

The organisation pleaded guilty and was without conviction sentenced to pay a fine of $30,000 and to pay costs of $4,420, with the Court noting a significant departure from expected safety standards, particularly given the foreseeability of the risk and the severity of the outcome. The serious and ongoing impact on the young worker was also a key consideration, alongside the importance of general deterrence in cases of this nature.

The organisation accepted responsibility, cooperated with the regulator, and it's Directors have since taken steps to improve its safety systems.

It is the overarching duty of every organisation to provide a WHS management system that ensures the safety and wellbeing of its workers. If you require support in improving or strengthening your WHS management system, Courtenell can assist through tailored training, consulting services, and management system review. Please contact one of our Training Consultants on 02 9552 2066 or email train@courtenell.com.au