HSE: Safe Use of Flammable Liquids

Solution: Safe use means controlling ignition sources, limiting the amount of flammable liquid available to burn, providing safe storage and decanting arrangements, and ensuring competent people use suitable equipment and procedures. In UK law this is typically managed under DSEAR (Dangerous Substances and Explosive Atmospheres Regulations) and supported by HSE guidance on flammable liquids and dangerous substances.

In practice this usually includes: suitable containers, compatible dispensing, ventilation, clear labelling, fire precautions, spill response planning, and preventing releases to drains. HSE information on DSEAR and flammable liquids is a good starting point for the risk assessment approach.

Citations: HSE - DSEAR; HSE - Flammable liquids

Solution: Start with your inventory and Safety Data Sheets (SDS). Pay special attention to low flash point liquids, liquids used near hot work or electrical equipment, and any product decanted from bulk into smaller containers. Typical examples include petrol, solvent-based paints, thinners, IPA, acetone and many adhesives. Where vapours can build up (workshops, stores, confined areas), controls should be stricter due to increased ignition risk.

Use your SDS to confirm key properties like flash point, flammability classification, and incompatibilities. Then set controls for storage, segregation, decanting and spill response based on the highest risk activities.

Solution: Store flammable liquids in suitable, labelled containers and keep quantities to the minimum needed for operations. Use a designated flammable store or approved flammable storage cabinets where appropriate, maintain good ventilation, and keep away from ignition sources. Segregate incompatible chemicals and keep escape routes clear.

From a spill management perspective, storage should also prevent loss of containment from reaching the environment. Where drums, IBCs or multiple containers are stored, add secondary containment such as bunded areas, bund pallets or bunded shelving. This reduces clean-up time, supports environmental compliance and can help demonstrate robust controls during audits.

See also our practical guidance on oils handling and spill prevention: Oil spill prevention and control.

Solution: Plan decanting to reduce spills and vapour release. Use appropriate dispensing equipment, avoid open funnels where possible, and keep containers closed when not in use. Work in well-ventilated areas, control ignition sources, and use anti-static precautions if required by your risk assessment (for example, bonding and earthing during transfer of certain flammable liquids).

Make spill control part of the decanting station: place dispensing on a drip tray or bunded work surface so minor drips do not become floor contamination. If your site uses multiple products, label the area clearly and keep compatible absorbents close by so response is immediate.

Solution: Choose spill kits by liquid type, spill size, and location. For mixed site liquids, a general purpose spill kit is often used for everyday drips and leaks. For hydrocarbons (fuels, oils, many lubricants), an oil-only spill kit repels water and targets hydrocarbons, making it effective outdoors and near rainwater. For aggressive solvents, confirm absorbent compatibility and consider specialist absorbents where required by the SDS.

Position spill kits where risk is highest: decant points, stores, loading bays, plant rooms and waste areas. Include drain protection where spills could enter surface water or foul drains. If a spill can reach a drain in seconds, drain covers or drain mats should be within immediate reach.

Related internal guidance: Oil spills and response.

Solution: Use a layered approach: prevent, contain, protect drains, then clean up. Secondary containment (bunding, bund pallets, drip trays) helps keep liquids in a controlled area. For higher risk locations, add drain protection (for example, drain covers) so a spill does not reach watercourses.

Operational example: a maintenance workshop storing solvents and fuels near a yard drain should use bunded storage for containers, a drip tray under dispensing, and a drain cover stored next to the exit to the yard. This helps meet site environmental objectives and reduces the chance of reportable incidents.

Solution: Keep the procedure clear and rehearsed. It should typically cover: raising the alarm, isolating ignition sources if safe, evacuating where necessary, using suitable spill kits and drain protection, and disposing of contaminated absorbents as controlled waste where applicable.

Train staff to recognise when a spill is beyond first response, especially if vapours are strong, the spill is spreading quickly, or ignition risk is elevated. Ensure you have suitable fire precautions and that spill response does not create additional hazards.

Citations: HSE - DSEAR; HSE - Flammable liquids

Solution: HSE and insurers expect evidence of risk assessment, suitable controls and competence. You can strengthen compliance by documenting: your flammable liquids inventory, DSEAR assessments where needed, storage and handling procedures, inspection records for containers and bunding, spill kit locations, training records, and incident response drills.

For environmental compliance, demonstrate that you can contain leaks and prevent drain entry. Bunding, drip trays, drain protection and correctly selected spill kits are practical controls that auditors can verify quickly on site.

Solution: Common issues include overstocking flammable liquids at the point of use, storing containers without secondary containment, decanting over bare floors, spill kits located too far away, and no drain protection near high-risk areas. Fix these by reducing quantities, adding bunding and drip trays, creating a designated dispensing point, relocating spill kits to the risk, and placing drain covers where a spill could reach drains.

If you are unsure where to begin, start with a simple walk-through: identify where flammable liquids arrive, where they are stored, where they are transferred, and where they could escape to drains. Then apply containment, spill response and drain protection at those points.