COSHH Risk Assessment: A Complete UK Workplace Compliance Guide

How do I actually complete a COSHH risk assessment in the UK? This is the most common question business owners ask today. You want to keep your workers safe, but the paperwork feels hard. However, getting it wrong is very expensive. In fact, HSE fines averaged £18,500 in 2024 for COSHH failures. That is a lot of money to lose.

But do not worry. By the end of this guide, you will have a compliant assessment. Not only will we help you find a free COSHH assessment template, but we’ll also break down the 2025 regulations into simple, easy-to-understand terms. This guide was written for everyone, using clear English so you can follow every step. Let’s make your workplace safe together.

What Is a COSHH Risk Assessment And Why Does It Matter In UK Workplaces?

A COSHH hazard assessment is a careful check of your workplace. You look for things that can hurt people’s health. In the UK, this comes from the Control of Substances Hazardous to Health Regulations 2002. The law says you must control bad chemicals. This keeps your workers from getting sick.

For 2025, the Health and Safety Executive (HSE) has new focus areas. They are looking closely at vape liquids in factories. They are also checking liquids that cause hand-arm vibration issues. Also, limits for respirable crystalline silica (RCS) are reduced again. This dust is very dangerous for lungs.

So, who needs to do this? Literally every UK workplace that uses chemicals needs one. This includes small hair salons using dyes. It includes big construction sites with dust. If you use glue, paint, or bleach, you need a COSHH safety check.

What UK laws require You to Carry Out a COSHH Hazard Assessment?

The main law is the COSHH Regulations 2002. These rules tell you how to handle dangerous substances. They say you must prevent exposure to these items. If you cannot prevent it, you must control it.

This law links to the Health and Safety at Work etc. Act 1974. This Act is the big grandfather of safety laws. It says an employer must ensure safety. Therefore, failing COSHH means you also break the main safety act.

The HSE creates guidance and enforces these laws. They have inspectors who visit workplaces. If you don’t comply, bad things happen. You could face unlimited fines. You could even go to prison. Also, your business reputation will suffer.

When Do You Legally Need a COSHH Risk Assessment?

You might think your shop is safe. However, many common items are actually dangerous. You legally need a COSHH safety review if you have these triggers.

Here is a list of common triggers:

• Cleaning chemicals: Bleach and strong floor cleaners are hazardous.
• Welding fumes: The smoke from welding metal hurts lungs.
• Wood dust: Cutting wood creates dust that causes asthma.
• Solvents, paints, adhesives: These give off fumes that make you dizzy.
• Biological agents: This includes legionella bacteria in water pipes. It also covers healthcare settings.
• Lead and asbestos: These have their own laws, but COSHH applies too.

If you have any of these, you must act. Ignoring them is against the law.

How Do You Carry Out a COSHH Risk Assessment Step by Step?

Doing a COSHH safety review is not a mystery. You just need to follow a logical path. Here are the five steps you must take.

Step 1: Identify hazardous substances in your workplace

First, walk around your workplace. Look for bottles with warning diamonds. These are red and white shapes on the back. Read the labels carefully. Look for Safety Data Sheets (SDS). These sheets tell you exactly what is inside. Make a list of everything you find.

Step 2: Decide who could be harmed and how

Next, think about your people. Who uses these chemicals? Is it cleaner? Is it the painter? Also, think about people nearby. Visitors or office staff might breathe in fumes. Think about how the harm happens. Do they breathe it in? Does it touch their skin? Do they swallow it by mistake?

Step 3: Evaluate existing controls and decide on further actions

Now, look at what you are doing currently. Are you doing enough? Perhaps you open a window. Maybe the staff wear gloves. You must compare this to the law. Is the window enough? Are the gloves the right type? If the risk is still high, you must do more. You need to add better controls.

Step 4: Record your COSHH findings and control measures

You must write down your findings. If you have five or more staff, this is a legal requirement. However, writing it down is good for everyone. Use a simple form. Write down the hazard. Write down the risk. Then, write down how you fix it. This is your proof of safety.

Step 5: Review and update your COSHH risk analysis regularly

Workplaces change all the time. You might buy a new cleaner. You might hire new staff. Therefore, you cannot just do this once. You should check your assessment every year. Also, check if an accident happens. Keep your COSHH risk analysis fresh and up to date.

What Control Measures Are Required Under a COSHH Risk Analysis?

When you find a risk, you must fix it. But you cannot just choose any fix. You must follow a specific order. This is called the hierarchy of control.

• Elimination: The best way is to get rid of the chemical.
• Substitution: Can you use a safer chemical? For example, use water-based paint instead of oil-based.
• Engineering Controls: This means using machines to help. You might install a ventilation fan. You might use a machine that sucks up dust.
• Administrative Controls: This changes how people work. You might make rules about time limits.
• PPE (Personal Protective Equipment): This is the last resort. Masks and gloves are the final defence.

Ventilation is very important. Fresh air moves fumes away. Substitution is also powerful. It removes the danger at the source.

You must use PPE correctly under COSHH. It must fit the worker. A mask that is too big does not work. Also, you must store it cleanly. Dirty PPE can actually cause harm.

Who Is Responsible for COSHH Risk Assessments in the UK?

Safety is a team effort. However, the law gives specific jobs to specific people.

• Employer duties: The boss is mainly responsible. The employer must ensure the COSHH risk analysis happens. They must provide the time and money. They must provide the training. If something goes wrong, the employer is usually liable.
• Employee responsibilities: Workers have duties too. They must follow the rules. They must wear the PPE provided. If they see a broken machine, they must report it. They must not be reckless with chemicals.
• Competence: Who can carry out a COSHH risk analysis? You do not always need an expensive expert. A competent person can do it. This means someone with knowledge and experience. Often, a manager or supervisor can do it. They just need to understand the work and the risks.

What Does a Good COSHH Risk Analysis Template Look Like?

You do not need a complicated book. A good template is clear and simple. It should be easy to read in a hurry.

Essential sections a UK COSHH form should include:

• Product Name: What is the substance?
• The Hazard: What does it do? (e.g., burns skin).
• Who is at risk: (e.g., cleaners).
• Control Measures: What are we doing about it?
• First Aid: What to do if it goes wrong.
• Disposal: How to throw it away safely.

Example of a simple COSHH risk assessment entry:

Digital vs paper COSHH records:
Which is better? Paper is easy to grab. You can stick it on the wall. However, paper gets lost or dirty. Digital records are safe on a computer. They are easier to update. Many companies now use apps. Both are legal. Choose the one your staff will actually use.

How Do You Train Staff On COSHH Risk Assessments and Safe Use Of Chemicals?

Writing the assessment is only half the job. You must tell your staff about it.

Legal requirements for information, instruction and training

The law says staff must know the risks. They must know how to use controls. You must teach them how to handle spills. If you do not train them, the assessment is useless.

Inductions, toolbox talks and refresher training:

Start when a new worker joins. This is the induction. Show them the hazards immediately. Then, have “toolbox talks.” These are short, 10-minute chats. Do them once a month. Remind them about masks or washing hands. Finally, do refresher training every year. People forget things over time.

How to check that COSHH controls are actually being followed:

Don’t just trust; you must check. Walk around the floor. Are people wearing their gloves? Is the ventilation turned on? If not, correct them gently. Ask them why they stopped. Maybe the gloves are uncomfortable. Fix the problem to improve safety. 

7 Real COSHH Risk Assessment Examples

To help you understand, let’s look at real life. Here are seven examples you might see in 2025.

1. Bleach in a school cleaning cupboard

• Hazard: A cleaner uses strong bleach for toilets. It creates fumes and burns skin.
• The Assessment: The COSHH risk assessment notes the danger of splashing.
• Control: The school buys pre-diluted bleach. This is safer than mixing it. The cleaner wears long rubber gloves. They keep the door open for air.

2. Isocyanate paint in a bodyshop

• Hazard: A car sprayer uses paint with isocyanates. These cause severe asthma.
• The Assessment: This is a high-risk chemical.
• Control: The worker uses a spray booth. The booth sucks the air away. The worker wears an air-fed mask. This pumps clean air to their face. They have lung health checks every year.

3. Hardwood dust in a joinery workshop

• Hazard: A carpenter cuts oak wood. The fine dust causes cancer.
• The Assessment: Dust is filling the air.
• Control: The saw has a vacuum attached. This is Local Exhaust Ventilation (LEV). The workshop is cleaned with a vacuum, not a broom. Brooms just push dust into the air.

4. Glutaraldehyde in an endoscopy unit

• Hazard: Hospital staff clean medical tools. They use a strong chemical called Glutaraldehyde.
• The Assessment: It causes breathing problems.
• Control: They use a washing machine for tools. This is a closed system. Staff do not touch the liquid. They only handle the sealed bottles.

5. Welding fumes on a construction site

• Hazard: A welder joins steel beams. The smoke contains metal oxides.
• The Assessment: The smoke is thick and bad for lungs.
• Control: The welder uses a mobile fume extractor. They move the nozzle close to the weld. They also wear a mask under their welding helmet.

6. Hairdressing peroxide & dust

• Hazard: A stylist mixes hair bleach powder.
• The Assessment: The powder puffs into the air. It hurts the nose.
• Control: They mix it in a separate room. The room has a fan. They wear disposable gloves. They use a “dust-free” type of powder.

7. Silica dust from cutting engineered stone worktops

• Hazard: This is a big 2025 focus. Cutting stone worktops creates silica dust.
• The Assessment: Silica dust stays in lungs forever. It kills.
• Control: Dry cutting is banned. They use water to wet the blade. This turns dust into mud. The mud is safe. The worker also wears a high-grade FFP3 mask.

What are Common COSHH Risk Assessment Mistakes (And How Can You Avoid Them)?

Even smart people make mistakes. Here are common errors to watch for.

Relying only on PPE:

Many bosses just buy masks. They think, “Job done.” This is wrong. Masks are the last choice. You should try to remove the danger first. Masks are uncomfortable and often fail.

Copy‑and‑paste assessments with no site‑specific detail:

Do not just download a form and sign it. Your workplace is unique. A generic form might miss your specific hazards. You must add your own details. Mention your specific machines and rooms.

Ignoring non‑routine tasks:

You check the daily jobs. But what about the odd jobs? What about when the cleaner spills a bucket? What about when the machine breaks? Accidents happen during these times. Your COSHH safety assessment must cover maintenance and emergencies too.

How Can Small UK Businesses Manage COSHH Risk Assessments Effectively?

You are a small business. You do not have a safety manager. How do you cope?

Practical tips for SMEs with limited resources

Keep it simple. You do not need a 100-page book. Group your products. For example, group all “toilet cleaners” together. Assess them as one group. This saves time. Focus on the most dangerous things first.

Free HSE COSHH tools and guidance

The UK government helps you. The HSE website is full of free tools. They have “COSHH Essentials.” These are sheets that tell you exactly what to do. You type in your industry. They give you the answer. It is free and legal.

When to get external help or a consultant

Sometimes, it is too hard. Maybe you have very strange chemicals. Maybe you have high-risk fumes. If you are confused, get help. Hiring a consultant costs money. However, a fine costs much more. It is a good investment for peace of mind.

Final Thought On COSHH Risk Assessment Checklist: What Should You Do Next?

To finish, here is a quick checklist you can follow today.

COSHH Safety Review checklist for UK workplaces

• List every chemical, dust, fume, gas, mist and vapour used
• Get Safety Data Sheets and understand each substance’s main hazards clearly
• Decide who could be harmed, including cleaners and occasional visitors
• Choose controls using the COSHH hierarchy, not just more PPE
• Record everything using a clear, simple COSHH assessment template
• Train staff on the risks and the controls they must follow
• Check that controls are actually working during normal work and breakdowns
• Review assessments yearly, or when work, substances or laws change

Next, prioritise your highest‑risk substances and tasks for action.
For many businesses, that means welding fumes, silica dust or strong cleaners.

For official guidance, search online for “HSE COSHH” and use their resources.
With steady effort, your danger evaluation will stay simple, legal and effective.

FAQ

1. What are the 5 steps of a COSHH risk assessment?

• Identify hazards, decide who may be harmed, evaluate risks and controls, record findings, review regularly.

2. What are the 10 golden rules for COSHH?

• Assess risks, substitute safer substances, read safety data sheets, use controls, wear PPE, train staff, label/store safely, maintain hygiene, prepare for emergencies, review risks.

3. Who must complete a COSHH risk assessment?

• The employer or a competent person appointed by the employer.

4. What is the full form of COSHH?

• Control of Substances Hazardous to Health.

5. What are the 5 P’s of risk assessment?

• People, Processes, Plant, Procedures, Products.

6. What are the three main requirements of COSHH?

• Assess the risks, control exposure, monitor and review controls.