The Hierarchy of Hazard Controls: What It Is and How to Implement It

Written by Staff Writer | Edited by Nate Bortz

Workplace safety is a critical priority in trade and professional services. Ensuring a safe environment requires understanding and implementing effective measures for managing risks.

One widely recognized approach is the hierarchy of controls, a framework designed to prevent and mitigate workplace hazards.

This guide explains what the controls are and how to implement them in order to create a safer work environment.

What Is the Hierarchy of Controls?

The hierarchy of controls is a system used to minimize or eliminate hazardous exposures in the workplace. Developed by occupational safety experts, it prioritizes hazard prevention methods in a structured order, starting with the most effective solutions.

The Occupational Health and Safety Administration (OSHA) categorizes these measures into five levels:

• Elimination: Physically removing hazards
• Substitution: Replacing hazards
• Engineering Controls: Isolating workers from hazards
• Administrative Controls: Changing the way people work
• Personal Protective Equipment (PPE): Protecting workers with PPEs

Under the General Duty Clause of the OSH Act, employers have a responsibility to provide their workers with a safe environment and proper training. Taking a systematic approach to hazard control not only protects workers from harm but also safeguards your business from potential legal and financial repercussions associated with accidents.

Understanding Each Control Level

Each level of the hierarchy plays a unique role in hazard control, and understanding these levels is essential for developing a comprehensive safety strategy. Let's begin with the first: elimination.

Elimination

Eliminating hazards is the most effective occupational safety control measure. This involves identifying risks during the planning stages of a project or process and designing solutions that prevent those risks.

Your strategy might include:

• Conducting a thorough risk assessment and hazard identification
• Modifying workflows or procedures and avoiding hazardous activities
• Replacing old machinery or materials with safer alternatives

Elimination strategies reduce both the cost and complexity of hazard management. For example, when constructing a new manufacturing plant, using textured, slip-resistant materials for the floors can eliminate the risk of falls in high-traffic areas. This is far more efficient than addressing the hazard after an accident occurs, which could involve compensating an injured worker and disrupting operations to remove existing flooring.

Substitution

If you can't eliminate hazards, the next step is substituting materials, processes or equipment with something less dangerous.

Substitution could include:

• Replacing harmful chemicals with non-toxic alternatives
• Using quieter machinery, reducing noise-related risks and complying with hearing conservation regulations
• Implementing automated tools and limiting manual handling of hazardous substances

Once a substitution is made, monitor its effectiveness and verify that it does not introduce new hazards into the workplace.

Engineering Controls

When elimination or substitution isn't possible, engineering controls provide a barrier between workers and the hazard. These controls don't rely on individual behavior and effectively reduce exposure.

Examples include:

• Installing ventilation systems to remove airborne contaminants
• Using machine guards to prevent contact with moving parts
• Implementing lockout/tagout systems to ensure machinery cannot operate during maintenance

Consider partnering with a certified safety engineer to pinpoint where controls will be most effective and install systems tailored to specific hazards. Additionally, schedule routine inspections to check that the equipment continues to function as intended.

Administrative Controls

Administrative controls involve changes to workplace policies, procedures or schedules to reduce exposure to hazards. These measures require worker compliance and are often used in combination with engineering controls.

Examples:

• Rotating employees to minimize time spent in hazardous conditions
• Implementing mandatory safety training programs, such as OSHA 10-Hour Training or 30-Hour Training
• Establishing clear procedures for handling common hazards, such as fall prevention or electrical hazards

For the best results, engage employees in safety committees to ensure that policies are practical and address challenges they face in their day-to-day tasks.

Personal Protective Equipment (PPE)

Personal protective equipment (PPE) includes gear like helmets, goggles and respirators that protect workers from residual risks.

While PPE is essential, it's important to remember that it should not be the primary method of hazard control. You should exhaust all other tiers in the hierarchy first. If PPE is still necessary, employers should provide the necessary safety equipment for workers.

Best Practices for PPE:

• Provide the appropriate PPE for each task. For example, learn what PPE is required in construction.
• Ensure PPE is properly fitted and maintained
• Train employees on the correct usage and disposal of PPEs. Certification courses like the PPE Certificate Training can be invaluable.

An Example of The OSHA Hierarchy of Controls in Action

Let's take a closer look at how the controls can be applied. In this example, we'll focus on the steps you can take to prevent falls from heights in the construction industry:

• Elimination: Design buildings and structures to minimize work at heights, such as prefabricating components on the ground.
• Substitution: Use mobile elevated work platforms instead of ladders when possible.
• Engineering Controls: Install guardrails, safety nets and anchor points for fall arrest systems.
• Administrative Controls: Develop and enforce a fall protection plan and provide fall prevention training.
• PPE: Equip workers with harnesses, lanyards and helmets with chin straps.

Using Training to Mitigate Common Workplace Accidents and Injuries

Using hazard controls along with workplace training is a great way to provide multiple layers of protection against OSHA's Top 10 violations. Training employees on control measures ensures they understand their roles in maintaining a safe environment.

All OSHA Education Center training is available online, so employees can work at their own pace from any connected device. Learners can stop and start courses at any time and many offer instant access to a completion certificate.

Explore our Enterprise Safety Solutions to find a training course that works best for your business.