Spill Kits UK — COSHH Compliance Guide

Spill kits are not optional equipment in UK workplaces — they are a legal requirement wherever hazardous liquids are used, stored, or handled. This guide explains the legal framework, how to choose the right kit for your workplace, how many kits you need, how to use them correctly, and what training your staff require. Written for compliance managers, health and safety officers, and business owners across all sectors.

Legal Requirements for Spill Kits in UK Workplaces

Two key pieces of UK legislation require spill response equipment in workplaces handling hazardous liquids:

COSHH Regulations 2002

The Control of Substances Hazardous to Health Regulations 2002 (COSHH) require employers to assess and control the risks arising from hazardous substances in the workplace. Regulation 7 requires employers to prevent or, where prevention is not reasonably practicable, adequately control exposure to hazardous substances. This explicitly includes the risk of accidental spills and their impact on workers and the environment.

A spill kit is a core control measure under COSHH for any workplace handling oils, fuels, chemicals, acids, alkalis, solvents, or other hazardous liquids. The quantity and type of kit required should be determined by your COSHH risk assessment.

Environment Agency PPG2

PPG2 (Pollution Prevention Guidance: above ground oil storage) requires that any site storing or handling oil or fuel has adequate spill response capability. The guidance specifies that spill response equipment should be immediately accessible, adequate for the quantities stored, and regularly maintained.

Health and Safety at Work Act 1974

Section 2 of HSWA requires employers to provide a safe working environment and adequate facilities for welfare. Spill response equipment falls under this duty where spills present a risk to worker health or safety.

Types of Spill Kit

Oil-Only Spill Kits

Oil-only spill kits contain white hydrophobic (water-repellent) absorbents: pads, socks, booms, and pillows. These materials absorb hydrocarbons (oil, fuel, lubricants, hydraulic fluid) while actively repelling water. This makes them ideal for:

• Outdoor use — rain and surface water do not reduce absorbent effectiveness
• Workshop and garage floors — absorb oil while leaving water behind
• Fuel storage areas and tanker offloading zones
• Drainage channel and watercourse emergency response
• Forecourts and vehicle maintenance areas

Chemical Spill Kits

Chemical spill kits contain universal absorbents: typically grey or yellow pads and socks rated for use with acids, alkalis, solvents, corrosives, and most industrial chemicals. They absorb a wider range of liquids than oil-only kits but are not hydrophobic. Use for:

• Laboratory and chemical processing environments
• Acid and alkali storage areas
• Pharmaceutical and research facilities
• Any location handling corrosive or reactive chemicals

General Purpose / Maintenance Spill Kits

General purpose kits contain universal absorbents and are designed for mixed-use environments where a variety of liquids may be spilled. Typically used in:

• Maintenance workshops with mixed chemical and oil hazards
• Factories and manufacturing facilities
• Warehouses with multiple product types

Specialist Spill Kits

Some applications require specialist kits: HazMat kits for unknown or highly hazardous substances; biohazard kits for body fluids in healthcare; or large-volume outdoor kits for major spill response. Consult your COSHH assessment and emergency response plan to determine if specialist kits are required.

How to Choose the Right Spill Kit

Step 1: Identify the Hazard

What liquids are present? Are they hydrocarbon-based (oil, fuel) or water-based (chemical solutions)? Could they be reactive with water or other chemicals? Your COSHH assessment should identify all hazardous liquids on site.

Step 2: Match the Absorbent Type

Liquid Type	Recommended Kit
Engine oil, diesel, kerosene, hydraulic fluid	Oil-only (white absorbents)
Acids, alkalis, solvents, corrosives	Chemical (universal or hazmat absorbents)
Mixed / unknown	General purpose (universal absorbents)
Water-miscible chemicals	Chemical or general purpose
Outdoor use, wet environments	Oil-only (if hydrocarbons) or chemical

Step 3: Size the Kit

Match kit capacity to your maximum foreseeable spill volume:

• 10-20 litres — minor leaks, small containers, personal protective kit
• 50 litres — small drum or intermediate tank area
• 100 litres — vehicle maintenance, fuel dispensing, small chemical storage
• 200 litres — 205-litre drum storage, larger chemical handling areas
• 240+ litres (wheeled bin) — IBC storage, tanker offloading, large volume operations

Step 4: Choose the Container

• Grab bag — portable, for emergency response or vehicle kits
• Wheeled bin — high capacity, easy to manoeuvre to spill location
• Sack — lightweight, low cost, suitable for small areas with limited access
• Trolley-mounted — for frequent or large-scale spill response

Spill Kit Placement Guide

How Many Kits?

Your COSHH risk assessment should specify the minimum number of kits. As a practical guide:

• One kit per hazardous substance storage area
• Minimum one kit within 10 metres of any dispensing or transfer point
• One kit per floor in multi-storey facilities with chemical hazards
• Vehicle-mounted kit for any vehicle transporting hazardous liquids

Where to Position Kits

• Within 10 metres of the spill risk — never further than a 30-second walk
• Clearly labelled and visible — not hidden behind equipment or in locked storerooms
• Away from the hazard itself — positioned so it can be reached before the spill area
• Near emergency exits — responders should not have to cross the spill to retrieve the kit
• At or near secondary containment — spill tray, bund, or palletised storage area

Maintenance and Restocking

After Use

Spill kits must be fully restocked immediately after any use. Do not return a partially used kit to service — it will not provide adequate response in the next incident. Keep replacement absorbents in stock at all times.

Regular Inspection

Inspect all spill kits at least quarterly as part of your COSHH management plan:

• Check contents are complete and undamaged
• Verify absorbents have not been used or contaminated
• Check PPE (gloves, goggles) included in the kit are in date and undamaged
• Confirm disposal bags and ties are present
• Check the kit container/bin is intact and the lid seals

How to Respond to a Spill — Step-by-Step

1. Assess the situation — identify the liquid, quantity, and direction of flow. Is there a risk to drains or watercourses?
2. Alert colleagues — ensure others are aware; restrict access to the spill area
3. Don PPE — at minimum: chemical-resistant gloves and eye protection. For chemicals: face shield and apron
4. Stop the source — close valves, right over containers, or isolate the supply if safe to do so
5. Prevent spread — place absorbent socks or booms around the perimeter to contain the spill
6. Absorb the liquid — apply absorbent pads from the outside in, working toward the centre
7. Collect and bag — place used absorbents in the disposal bags provided; seal and label
8. Decontaminate the area — apply further absorbent if required; check drains for contamination
9. Dispose of waste correctly — used absorbents containing hazardous substances are hazardous waste; dispose of via a licensed contractor
10. Report and record — complete an incident report; investigate root cause; restock the kit

Training Requirements

COSHH Regulations require employers to provide adequate information, instruction, and training to employees who may be exposed to hazardous substances — including training in spill response. As a minimum:

• All staff in areas where spill kits are located should receive basic spill awareness training
• Designated first responders should receive practical spill response training covering the step-by-step procedure above
• Training records should be maintained and refreshed annually or after any significant incident
• The COSHH risk assessment should specify training requirements for each substance or area

HSE and the Environment Agency both recommend that all spill response team members can demonstrate competence in the use of spill kits before working in areas with significant spill risk.

Frequently Asked Questions

What size spill kit do I need?

Select based on the maximum foreseeable spill volume at your site. Kits range from 10-litre grab bags for minor incidents to 240-litre wheeled bins. Your COSHH risk assessment should specify the minimum response capability required.

Are spill kits a legal requirement in the UK?

Yes — under COSHH Regulations and EA PPG2 guidance, any workplace handling hazardous liquids must have appropriate spill response equipment immediately available. Failure to comply can result in HSE enforcement action.

What is the difference between oil and chemical spill kits?

Oil-only kits use hydrophobic (water-repellent) absorbents that absorb hydrocarbons but repel water — ideal for outdoor use. Chemical kits use universal absorbents rated for acids, alkalis, solvents, and corrosives.

How often should spill kits be restocked?

Immediately after any use. Partially used kits should be fully restocked before returning to service. We recommend a quarterly inspection as part of your COSHH management plan.

Can I get next day delivery on spill kits?

Yes — all spill kits are held in UK stock and available for next day delivery when ordered before 3pm.