COSHH Assessments: 7 Common Mistakes Employers Make (and How to Fix Them)

COSHH isn't just paperwork - it's about maintaining control. A COSHH assessment should answer one question: Are you protecting your employees from hazardous substances at work? Often, these assessments become a simple formality - they get filed away, rarely checked, and have nothing to do with the reality of the workplace. This is where the danger starts.

Here are seven frequent COSHH mistakes we see, along with ways to apply better practices.

1) Treating COSHH as a one-time thing. Many COSHH assessments are done once and then forgotten. But businesses change:

• You start using new materials.
• Production goes up or down.
• Work changes.
• Teams change, and people find shortcuts.

Solution: Check COSHH assessments often, especially after any kind of business change.

2) Depending on basic templates. Templates can be useful, but they don't replace knowing your business. A basic COSHH assessment often misses:

• How exposure actually happens.
• How long and how often tasks take.
• How controls are really used.
• If you can depend on maintenance.

Solution: Make COSHH specific to each task, not just each product.

3) Thinking PPE is enough. PPE is important, but it should be your last option. If your COSHH assessment mostly says:

• Wear gloves.
• Wear a mask.
• Wear goggles.

Then you might not be controlling the risk well enough.
Solution: First, try to remove the hazard, then substitute it, use machine controls, and create safe work systems before you rely on PPE.

4) Not checking if controls actually work. Just because a control is there doesn't mean it's doing its job. LEV systems can lose power. Filters can break down. Work habits can slip. RPE might not fit right. People might turn off extraction because it's loud or annoying.
Solution: Inspect, test, and check exposure to make sure controls are doing what they should.

5) Not understanding how exposure happens. COSHH risk isn't only about breathing things in. Many substances can harm you through:

• Skin
• Eyes
• Swallowing (dirty hands or food)
• Soaking through skin.

Solution: Check every possible way exposure can happen, and make sure your controls match the real risks.

6) Missing worst-case tasks. Some tasks don't happen often but can have higher exposures, for example:

• Cleaning and maintenance
• Spill cleanup
• Filter replacement
• Working in tight spaces
• Short tasks that make a lot of dust.

These are often overlooked because they're not part of the daily work.

Solution: Know which tasks aren't routine and add them to your COSHH plan.

7) Not connecting COSHH to real training and supervision. A COSHH assessment only works if your people get it and follow it. Common problems:

• Workers don't know why controls matter.
• RPE isn't worn right.
• Poor housekeeping
• Unsafe fixes become normal.

Solution: Back up COSHH with training, supervision, and simple rules about how to act.

What Good COSHH Looks Like
A good COSHH plan usually has:

• A clear list of hazardous substances and tasks.
• Useful controls that match the level of risk.
• Proof that controls work (testing and checking).
• Regular reviews and updates.
• Good training and clear responsibilities.
• Records that can be checked.It's not just about more forms.

It's about a system that protects your people and helps your business.

How Exposure Checking Adds Value
Exposure checking helps COSHH by:

• Showing if exposures are controlled well enough.
• Finding high-risk tasks.
• Helping you make good decisions.
• Clearing up guesses and assumptions.
• Providing proof for checks and clients.

It's often what's missing between a COSHH assessment and real risk control.

How Sysco Environmental Can Help. 

Sysco Environmental helps clients with:

• Checking workplace exposure.
• Helping with COSHH risk assessment.
• Giving tips for better controls.
• Creating plans that are based on facts and follow UK best practices.

We focus on solutions that provide support, can be put into action, and are trustworthy.

Want to make your COSHH better with real proof? If you want to check your COSHH assessments or make sure your controls really work, reach out to Sysco Environmental to talk about exposure monitoring and ways to improve.