OSHA Spill Kit Requirements: A Complete Guide

Any type of liquid spill can be a serious workplace hazard. When you’re working with acids, fuel, or other potentially dangerous substances, that hazard escalates — and you need to make sure that your employees have everything they need to contain and clean up the spill.

This is a legal requirement: The Occupational Safety and Health Administration (OSHA) requires that employers provide their workers with appropriate personal protective equipment (PPE).

But while OSHA requires PPE, there’s no set requirement for spill kits. Practically, that makes sense; to do so, the administration would need to organize lists of specific equipment for every potential type of spill. 

For employers, however, the lack of explicit requirements can make outfitting difficult. In this article, we’ll identify key spill response equipment that can help employers comply with OSHA standards — and more importantly, ensure safe and efficient cleanup when a spill occurs. 

If you’re simply looking for high-quality spill kits that aid in OSHA compliance, check out our full selection of Spill Response Kits & Supplies.

OSHA Spill Kit Requirements: Reviewing the Applicable Standards

A number of OSHA standards apply — directly or indirectly — to spill response. No standard specifically requires certain pieces of equipment outside of appropriate PPE (which we’ll discuss in a moment). 

The relevant standards include:  

• General Duty Clause, Section 5(a)(1) of the OSH Act: This broad (and frequently cited) clause requires employers to provide a workplace free from recognized hazards likely to cause death or serious physical harm. Chemical hazards certainly qualify.
• Hazard Communication Standard (29 CFR 1910.1200): This standard requires employers to inform employees about the hazards of the chemicals they work with, including how to safely handle and clean up spills. It also mandates providing appropriate PPE for handling hazardous chemicals.   
• Personal Protective Equipment (PPE) Standard (29 CFR 1910.132): This standard requires employers to assess workplace hazards and provide appropriate PPE to protect employees. 
• Hazardous Waste Operations and Emergency Response (HAZWOPER) Standard (29 CFR 1910.120): Applies to workplaces where employees are involved in cleanup operations involving hazardous substances. It requires employers to provide training and appropriate PPE.

Taken as a whole, these standards establish a few clear priorities for businesses that work with potential hazardous chemicals (including facilities with lift trucks, since vehicle batteries contain battery acid): 

• Employees need an ample supply of PPE, including gloves, eye protection, coveralls, and potentially respirators.
• Employees need supplies to contain and clean up spills while minimizing exposure.
• Employees must have access to emergency shower and/or eyewash stations (we cover those requirements in another article: Understanding OSHA Safety Shower Requirements).

Solus Group carries spill response kits that are specifically designed to address certain hazards while fulfilling those first two priorities (PPE and spill containment supplies). 

What Are “Appropriate" Supplies and PPE for Spill Response? 

OSHA is intentionally vague when discussing PPE — because there’s no one-size-fits-all option. The standards require “appropriate PPE for any hazards present.”

In interpretation letters, OSHA recommends performing a complete hazard assessment prior to outfitting. But for common chemical hazards (such as battery acid), the bare minimum PPE should include: 

• Eye Protection: Safety glasses or goggles.
• Hand Protection: Chemical-resistant gloves (nitrile or neoprene are standard for many types of chemical hazards). Learn how to choose chemical resistant gloves.
• Body Protection: Coveralls or a chemical suit can provide additional protection, though they may be overkill for certain types of spills.
• Foot Protection: Safety overshoes or boots with chemical resistance.

Don’t skip the hazard assessment: Some hazards may also require respiratory PPE (such as dust masks or respirators) or other interventions. 

Spill Cleanup Supplies: The Basics

On a practical level, spill response supplies should include these essentials:

• Pads and rolls: Flat absorbent materials used for smaller spills and wiping down surfaces.
• Adsorbent/absorbent socks: Tubular absorbents used to contain and direct the flow of liquids by creating barriers.
• Loose sorbents: Loose sorbents are excellent for containing, absorbing, and neutralizing certain hazardous liquids.
• Booms: Floating barriers used to contain spills on water surfaces.
• Neutralizing sorbents: These absorb and neutralize specific chemicals like acids and organic compounds.
• Brooms and waste disposal bags: For cleaning up and disposing of absorbed materials and other spill debris.

Products to Consider: 

Universal Spill Kits

Universal Spill Kits are designed to handle a wide range of liquid spills. 

Each kit includes fast-solidifying sorbents and UN/DOT-compliant packaging for a safe, efficient spill response. Standard kits include Super Sorbent in a 2-quart shaker carton, sorbent pads, sorbent socks, and disposal materials — all of the necessary tools for comprehensive spill management.

General-Purpose Spill Kits

For everyday spills, General Purpose Spill Kits offer a practical and cost-effective solution. These kits are equipped with a variety of absorbent materials, including loose sorbents, sorbent socks, and sorbent pads. Available in various configurations, including tote bags and tilt-wheel spill carts.

Oil Selective Spill Kits

Specifically designed for oil-based spills, Oil Spill Kits are essential for businesses that handle petroleum products. The oil-selective sorbents are ideal for cleaning up spills in virtually any environment, including spills that occur on water. 

Solus Group offers a wide selection of sizes and configurations to accommodate various spill volumes and operational requirements (including tote bags for vehicle use). 

Battery Acid Spill Kits and AcidSafe Spill Kits

AcidSafe Spill Kits provide a safe and effective solution for managing acid spills. Each kit contains specialized sorbents designed to neutralize acidic liquids (except hydrofluoric acid). 

Standard kits also include personal protective equipment (PPE) to ensure the safety of personnel during cleanup and disposal.

Personal Protective Equipment (PPE) Standard Kit

In addition to spill kits, Solus Group offers a range of PPE-only kits to safeguard personnel during spill response and cleanup. These kits include essential protective gear such as safety glasses, nitrile gloves, and chemical coveralls to shield workers from hazardous materials.

Building an OSHA-Compliant Spill Response Strategy: Frequently Asked Questions (FAQ)

Spill kits help you run a safer facility while simplifying outfitting. If you have questions about the best practices for addressing hazards at your facility, call our sales team at 314-696-0200 for guidance.

Below, we’ll address a few of the most common questions that employers ask when planning their spill response strategies. 

What size spill kit is right for my needs? 

When performing your hazard assessment, plan for the worst-case scenario. You should maintain enough supplies to handle several large spills. 

Have a process in place to order additional supplies as they’re used. Make that process a part of your training: Managers should understand that when spills are reported, the next step is to reorder supplies to maintain the stock. 

Where should spill kits be located in the workplace?

Spill kits should be in a highly visible location with clear signage. If possible, they should be close enough to potential spill sites to be easily accessible, but they shouldn’t get in the way of established travel paths.

Solus Group carries the BHS Security Cart, which provides secure, portable access to spill containment supplies, tools, and other high-value equipment. Custom lockers and carts are also available.

Related: How to Build a Chemical Spill Cart

What is the difference between absorbent pads and socks, and when should each be used?

Socks (along with booms) are used to contain spills by damming them in place. They’re ideal for directing the flow of liquids and protecting equipment and travel paths.  

Absorbent pads are essentially super-absorbent paper towels; they’re used to soak up small to medium-sized spills, or to wipe down equipment. They can also be placed under equipment to protect floors (though for lift truck batteries, we’d recommend AcidSorb pillows, which are specifically designed for the task). 

Do employees need special training to use spill kits?

Yes, you should provide training for any employees who may be assigned to spill response. 

A comprehensive spill response training course should include sections on:

• Identification of likely hazards. Be sure to include Safety Data Sheets (SDS) where necessary.
• Procedures for containing and neutralizing spills.  
• The proper ways to wear and remove (don and doff) personal protective equipment. 
• Proper disposal of hazardous waste. 

Document all training (including refresher training) in writing. OSHA inspectors may ask to review your emergency response plan and your PPE training process, and written logs may save you from a citation.  

How often should spill kits be inspected and replenished?

Spill kits with absorbents have a shelf life of about five years. However, the storage conditions matter; if you store them at room temperature and out of direct sunlight, they may last longer. 

You’ll need to inspect sorbents to make sure that they’re ready for use (and to ensure that you’re truly prepared for an emergency). Follow the manufacturer’s instructions; in general, sorbents are usable if they don’t have any white “flakes" or other signs of degradation. 

What are the proper disposal procedures for used spill kit materials?

This is dependent on the spill. A good rule of thumb: Absorbed materials take on the properties of the liquid they absorb, so treat them with the same care. Even when using neutralizing sorbents, exercise caution and give the neutralizer enough time to work.  

Follow local, state, and federal regulations. If a product uses UN/DOT-compliant packaging, that may be sufficient for disposal. Your local environmental agency (or, failing that, a waste disposal company) can provide additional guidance. 

To find the right spill kits, PPE, and other spill response supplies for your operation, call 314-696-0200 and speak with a member of our sales team.