How to Use a Spill Kit: A Complete Step-by-Step Guide
A spill kit is an essential safety resource in industrial, commercial, laboratory, and warehouse environments where hazardous or non-hazardous liquids are stored, transported, or handled.Knowing how to use a spill kit correctly ensures that spills are controlled, cleaned, and disposed of quickly, preventing workplace accidents, environmental damage, and costly downtime.
Whether the spill involves oil, chemicals, fuel, or water-based liquids, the proper spill kit procedure can minimise risks and maintain a safe working environment.
In this guide, we will explain in detail how to use a spill kit effectively, from identifying the spill type to disposing of contaminated materials safely.
The first step in using a spill kit is to identify the type of liquid spilled. Spill kits are typically designed for specific purposes—oil-only spill kits are used for hydrocarbon-based liquids such as diesel, petrol, or lubricants, while chemical spill kits are made for aggressive substances such as acids, alkalis, and solvents.
Universal spill kits, on the other hand, can handle a wide range of liquids, including water-based solutions, coolants, and oils.
Correctly identifying the liquid ensures that you choose the right absorbent materials and avoid chemical reactions that could make the spill more hazardous.
If the spilled substance is unknown or extremely dangerous, stop and alert trained hazardous materials (HAZMAT) personnel instead of attempting clean-up yourself.
Once you know the type of spill, the next priority is safety. Always put on the personal protective equipment (PPE) supplied in the spill kit or specified in your company’s safety protocol.
PPE may include gloves, safety goggles, respirators, or chemical-resistant aprons. Wearing the right PPE protects you from burns, chemical splashes, toxic fumes, or skin irritation. This is especially important for chemical spills, as even a small amount can cause severe harm if it contacts the skin or eyes.
After ensuring your safety, you should stop the source of the spill if possible. For example, if a container has tipped over, place it upright; if a hose or valve is leaking, shut it off.
Stopping the flow of liquid prevents the spill from growing and reduces the total clean-up time. In some situations, such as when dealing with high-pressure leaks or dangerous chemicals, it may not be safe to stop the source manually—if so, keep a safe distance and call for specialist assistance.
The next step is to contain the spill. Spill kits usually include absorbent socks, booms, or barriers designed to encircle the spill and stop it from spreading. Containment is critical in preventing the spill from reaching drains, waterways, or sensitive equipment.
If the spill occurs near a drain, place a drain cover or mat over the opening immediately. For large spills, create a perimeter using absorbent socks or booms, working from the outside in to gradually control the spread.
This step is especially important in oil spill response, where even small amounts of oil can cause severe environmental harm.
Once contained, apply the absorbent materials from the spill kit directly to the liquid. Absorbent pads are ideal for flat surfaces, while absorbent pillows can soak up larger volumes.
Loose absorbent granules are useful for uneven surfaces or small puddles. Spread the absorbent evenly over the spill, ensuring complete coverage. Depending on the volume, you may need to replace saturated absorbents with fresh ones until all the liquid is fully absorbed.
Using the right amount of absorbent ensures that the clean-up is effective and prevents slipping hazards.
After the spill has been absorbed, it is time to collect the used materials. This should be done using tools such as dustpans, brushes, or shovels provided in the spill kit or available in the work area. Place all contaminated absorbents into the disposal bags supplied with the kit.
Most spill kits include heavy-duty, labelled bags designed for hazardous or non-hazardous waste, depending on the liquid type. Always follow your local waste disposal regulations—chemical and oil-contaminated absorbents may require disposal by a licensed waste management company.
Once the main spill is removed, clean and decontaminate the affected area. This may involve using water, detergents, degreasers, or neutralising agents depending on the type of liquid spilled. For example, acid spills may require a neutralising powder, while oil spills may need a degreasing solution.
Cleaning the area thoroughly ensures no residue is left behind, reducing the risk of slips, chemical burns, or cross-contamination.
After cleaning, remove your PPE carefully to avoid contamination and dispose of any single-use protective equipment in the designated waste bags.
If reusable PPE such as goggles or boots was used, clean and store them properly for future use. This step is important for maintaining hygiene and ensuring your spill kit remains fully equipped.
The final stage of spill response is documentation. Record the details of the spill, including the type of liquid, the estimated volume, the location, the cause, and the actions taken during the clean-up.
This documentation is important for workplace safety audits, regulatory compliance, and insurance claims. It also helps identify whether additional training, equipment upgrades, or preventive measures are needed to avoid similar incidents in the future.
To ensure spill kits are always ready for use, they should be placed in accessible, clearly labelled locations close to potential spill hazards.
Conduct regular inspections to confirm that all components—absorbents, PPE, tools, and disposal bags—are present and in good condition. Replace any used or expired items immediately after use.
Training all relevant staff in spill response procedures is equally important. Regular drills help employees respond quickly and confidently in an actual spill situation, reducing panic and mistakes.
While the general steps for using a spill kit are similar across different types, some situations may require specialised procedures. For example, oil spills on water require floating booms and absorbent pads that repel water while absorbing oil.
Chemical spills involving volatile substances may require ventilation and vapour suppression. Mercury spills, which are extremely hazardous, require specialised mercury spill kits with vapour barriers and specific disposal protocols. In all cases, prioritising worker safety and environmental protection is essential.
GB 9238 
US 9155 
CA 8628 
AU 7606 
IE 5153 
BR 2412 
VN 1276 
NZ 914 
