UK COSHH Hazardous Substances Risk Assessment & Control Measures Audit [FREE PDF]

The Control of Substances Hazardous to Health (COSHH) Regulations 2002 require UK employers to assess and control risks from hazardous substances in the workplace. Employers must prevent or adequately control exposure to substances that may cause ill health, following the hierarchy of controls set out in Regulation 7. The HSE L5 Approved Code of Practice provides detailed guidance on conducting suitable and sufficient COSHH assessments, including identification of hazardous substances, evaluatio

  • Industry: UK Manufacturing
  • Frequency: Annually
  • Estimated Time: 45-60 minutes
  • Role: HSE Manager
  • Total Items: 35
  • Compliance: COSHH Regulations 2002 (SI 2002/2677), HSE L5 COSHH Approved Code of Practice (6th Edition), EH40/2005 Workplace Exposure Limits (4th Edition 2020), Workplace (Health, Safety and Welfare) Regulations 1992 (SI 1992/3004), Management of Health and Safety at Work Regulations 1999 Reg 3

Substance Identification & Inventory

Identify and record all hazardous substances present in the work area as required under COSHH Reg 6.

  • Has a complete inventory of all hazardous substances used in this work area been compiled?
  • Is a current Safety Data Sheet (SDS) available for each hazardous substance on site?
  • Are all substances clearly labelled in accordance with CLP Regulation labelling requirements?
  • Have any substances been substituted with less hazardous alternatives where reasonably practicable?
  • Are quantities of hazardous substances stored on site limited to operational needs only?

Exposure Assessment & Workplace Exposure Limits

Evaluate the nature, degree, and duration of employee exposure to hazardous substances.

  • Have Workplace Exposure Limits (WELs) been identified for all relevant substances using EH40?
  • Has air monitoring or exposure measurement been conducted where exposure to WEL substances is suspected?
  • Has the route of exposure been identified for each substance (inhalation, skin absorption, ingestion)?
  • Have the number of workers potentially exposed and their exposure frequency and duration been recorded?
  • Are any workers identified as being particularly at risk (e.g., young workers, pregnant workers, those with health conditions)?
  • Has the assessment considered non-routine tasks and maintenance activities involving hazardous substances?

Control Measures Implementation

Verify that appropriate control measures are in place following the COSHH hierarchy of controls.

  • Are engineering controls (e.g., local exhaust ventilation, enclosure) the primary control method where inhalation risk exists?
  • Are all LEV systems examined and tested at least every 14 months as required?
  • Are safe work procedures and systems of work documented and communicated to all relevant employees?
  • Is appropriate Personal Protective Equipment (PPE) provided where residual risks remain after other controls?
  • Is PPE stored correctly, inspected regularly, and replaced when necessary?

Health Surveillance & Biological Monitoring

Confirm health surveillance arrangements where required under COSHH Regulation 11.

  • Has it been determined whether health surveillance is required for workers exposed to substances listed in COSHH Schedule 6?
  • Where health surveillance is required, are records maintained for at least 40 years?
  • Has biological monitoring been considered for substances with significant skin absorption potential?
  • Are workers informed of health surveillance results and have access to their individual health records?
  • Is there a documented process for referring workers showing signs of work-related ill health to occupational health?

Information, Instruction & Training

Assess whether employees receive adequate information and training on COSHH risks and controls.

  • Have all employees who work with or may be exposed to hazardous substances received COSHH training?
  • Is COSHH training documented with records of attendees, content, and dates retained?
  • Are emergency procedures (spill response, accidental exposure, fire) communicated to all relevant workers?
  • Are COSHH assessment summaries displayed or readily accessible to workers in the relevant work areas?
  • Is refresher training provided when substances, processes, or controls change, or at a minimum every two to three years?

Emergency Arrangements & Incident Response

Verify emergency procedures are in place for incidents involving hazardous substances per COSHH Reg 13.

  • Are spill kits and containment equipment appropriate to the substances present readily available in the work area?
  • Are emergency eyewash stations and safety showers available where there is a risk of eye or skin contact with hazardous substances?
  • Are all incidents and near-misses involving hazardous substances recorded and investigated?
  • Is specific first aid provision in place that addresses the hazardous substances present on site?

Assessment Review & Documentation

Confirm COSHH assessments are properly documented, reviewed, and kept current.

  • Is the COSHH assessment documented in writing and readily accessible to all relevant parties?
  • Has the COSHH assessment been reviewed following any significant change in substances used, work processes, or control measures?
  • Are air monitoring records retained for the required periods (2 years for general monitoring, 40 years for specified substances)?
  • Has the COSHH assessment been signed off by a competent person and approved by management?
  • Is there an action plan with assigned responsibilities and target dates for any control measure improvements identified?

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Why Use This UK COSHH Hazardous Substances Risk Assessment & Control Measures Audit [FREE PDF]?

This uk coshh hazardous substances risk assessment & control measures audit [free pdf] helps uk manufacturing teams maintain compliance and operational excellence. Designed for hse manager professionals, this checklist covers 35 critical inspection points across 7 sections. Recommended frequency: annually.

Ensures compliance with COSHH Regulations 2002 (SI 2002/2677), HSE L5 COSHH Approved Code of Practice (6th Edition), EH40/2005 Workplace Exposure Limits (4th Edition 2020), Workplace (Health, Safety and Welfare) Regulations 1992 (SI 1992/3004), Management of Health and Safety at Work Regulations 1999 Reg 3. Regulatory-aligned for audit readiness and inspection documentation.

Frequently Asked Questions

What does the UK COSHH Hazardous Substances Risk Assessment & Control Measures Audit [FREE PDF] cover?

This checklist covers 35 inspection items across 7 sections: Substance Identification & Inventory, Exposure Assessment & Workplace Exposure Limits, Control Measures Implementation, Health Surveillance & Biological Monitoring, Information, Instruction & Training, Emergency Arrangements & Incident Response, Assessment Review & Documentation. It is designed for uk manufacturing operations and compliance.

How often should this checklist be completed?

This checklist should be completed annually. Each completion takes approximately 45-60 minutes.

Who should use this UK COSHH Hazardous Substances Risk Assessment & Control Measures Audit [FREE PDF]?

This checklist is designed for HSE Manager professionals in the uk manufacturing industry. It can be used for self-assessments, team audits, and regulatory compliance documentation.

Can I download this checklist as a PDF?

Yes, this checklist is available as a free PDF download. You can also use it digitally in the POPProbe mobile app for real-time data capture, photo documentation, and automatic reporting.

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