The Most Costly Spill Control Errors — And How to Fix Them
After years of working with UK businesses across manufacturing, logistics, construction, and processing industries, the same spill control mistakes appear time and again. Many are simple to fix; all of them carry serious consequences if left unaddressed — from Environment Agency enforcement notices and fines to workplace injuries, insurance invalidation, and criminal liability under the Water Resources Act 1991. Here are the top ten mistakes, and exactly what to do about each one.
- Using the wrong spill kit for the chemicals on site. Oil-only kits (white sorbents) do not absorb chemicals, and universal kits may degrade on contact with aggressive solvents. Always match your spill kit type — oil-only, universal, or chemical — to the substances actually present. Review your spill kits against your COSHH inventory at least annually.
- Undersizing secondary containment. PPG 26 requires 110% of the largest container or 25% of total stored volume. Many sites buy standard bunds without performing this calculation, leaving them under-compliant. Calculate before you buy, and revisit if storage volumes increase.
- Leaving bund drain valves open. An open drain valve negates the entire containment system. Valves must remain closed at all times except during controlled, supervised drainage operations. Lock valves closed and include valve status in every routine inspection.
- No spill response training for staff. COSHH requires employees to know how to respond to a spill. Equipment alone is not enough — staff must know where kits are located, how to use them, and when to escalate. Document training records and refresh annually.
- Spill kits that are depleted or out of date. A spill kit used and not restocked is worse than no kit — it creates a false sense of security. Inspect kits monthly. Restock immediately after any use. Absorbent materials have shelf lives; replace degraded stock.
- No drain protection. Without drain seals in position during a spill, liquid can reach the surface water or foul sewer network within seconds. Under the Water Resources Act 1991, this is a criminal offence. Install drain protection at all vulnerable points and ensure staff can deploy it instantly.
- Storing incompatible chemicals in the same bund. Mixing oxidisers and flammable liquids in the same secondary containment can create a reaction hazard. Segregate chemical storage by hazard class, and ensure bund design accounts for chemical incompatibility.
- Ignoring outdoor containment. IBC bunds and drum bunds stored outside face UV degradation, temperature cycling, and rainwater accumulation. Outdoor containment requires more frequent inspection, UV-stable materials, and management of accumulated water to maintain capacity.
- No emergency spill response plan. The Control of Major Accident Hazards (COMAH) Regulations and the Environmental Permitting Regulations both require written emergency plans for significant spill scenarios. Even smaller sites should have a documented response procedure covering notification of the Environment Agency (0800 80 70 60) and local authority.
- Buying on price alone. Cheap spill pallets, substandard absorbents, and uncertified containment products fail under real spill conditions. Specify products that are UN-approved where required, rated for your chemicals, and from reputable UK suppliers. The cost of a failed product during an actual incident vastly exceeds any purchase savings.
Building a Compliant Spill Control Programme
Avoiding these mistakes requires a structured approach: a current COSHH assessment, correctly specified and maintained equipment, trained and competent staff, documented inspection records, and a written emergency response procedure. This is not a one-off exercise — spill control compliance requires regular review as chemicals, processes, and staff change.
For a full audit of your current spill control provisions and recommendations for improvement, our team can advise on the right products for your specific site requirements. Explore our complete range of spill kits, spill pallets, drain protection, and absorbent materials.
Need expert advice? Call 01744 520 110