Hierarchy of Hazard Controls

Date Posted: 02/17/2024

The hierarchy of hazard controls pyramid is a systematic workflow to provide the most effective control measure for workplace hazards. The tool is used worldwide and prescribes a method to always begin with eliminating any hazards you identify in the workplace. The hierarchy of controls is helpful to aid workers in identifying the most effective way to control a particular hazard. Employers can use the hierarchy of controls to ensure they take the most effective measures to protect their employees from hazards. When faced with a specific hazard in the workplace, use the hierarchy of hazard control as a step-by-step process to determine the best action for controlling or eliminating the hazard. The hierarchy of controls is also helpful for developing a hazard control plan, where you can implement the selected controls in the workplace. The hierarchy of controls is an inverted pyramid with five levels, from most effective to least effective:

• Elimination – The physical removal of the hazard.

• Substitution – Replacing something that produces a hazard.

• Engineering Controls – Isolate people from the hazard.

• Administrative Controls – Change the way people work.

• Personal Protective Equipment (PPE) – Protect the workers with personal protective equipment (PPE).

What is a Hazard?

A hazard can be an object, a material, a substance, a condition, a process, or even a behavior. Some examples are falling from rooftops or heights, unguarded tools or machinery, being struck by heavy equipment, being caught in between hazards (such as unprotected trench or excavation), temperature extremes, and exposed electrical circuits or parts that may cause shock or electrocution.

Hazard Identification and Assessment Actions

Below are some hazard identification and assessment actions that should regularly be undertaken:

• Identify known hazards in the tools and equipment in your workplace.

• Conduct routine workplace inspections to identify any new hazards that specific work practices create.

• Investigate any injuries, incidents, illnesses, or near-miss events to identify the underlying hazard, dangerous work practice, or failure in your current safety program.

• Look for trends in types of injuries and illnesses to identify underlying hazards.

• Follow up to ensure the control measures you are using are effective.

• Encourage hazard reporting and empower employees to immediately fix any hazard when it is safe.

The Five Levels of the Hierarchy of Hazard Controls

Elimination

Elimination is the first level in the hierarchy of control and is considered the best way to control hazards. This involves completely removing the hazard from the workplace. Eliminating a hazard prevents any potential harm or injury from happening. However, the most effective elimination is also typically challenging to implement. 

Example: Redesign a process to perform tasks at ground level rather than work at heights.

Substitution

Substitution is the second most effective method of controlling a hazard. This involves replacing a hazard with a less hazardous one.

Example: Replace solvent-based paint with water-based paint. 

Engineering Controls

Engineering controls are the third level of control. Engineering controls involve isolating a hazard or changing how a task is performed to reduce exposure to a hazard. This often involves adding safety measures, such as installing machine guards, to make the work easier.

Example: Installing guardrails at work sites where workers work at heights.

Administrative Controls

Administrative controls are the fourth level of control. Administrative controls involve changing work practices or adjusting work tasks to reduce exposure to a hazard. This may include changing operational processes and work schedules or introducing signage or warnings in the workplace. Administrative controls can also include conducting hazard assessments through administrative tools like a JHA, JSA, job site inspections, etc.

Example: Limit workers’ exposure time to hazards and create formalized written operating procedures.

Personal Protective Equipment (PPE)

PPE is the fifth control level and the least effective hazard control method. PPE should only be used as the last line of defense when other forms of control are not possible or practical.

Example: PPE includes clothing, gloves, and other items that protect the body from hazardous exposure.

Don’t Forget to Review Hazard Control Measures!

Review your control measures to ensure they are relevant and keep workers safe. When reviewing hazard control measures, consider the following:

• Are the control measures working effectively in both their design and operation?

• Are the control measures creating new problems or hazards?

• Are you missing any hazards?

• Are the new work methods, equipment, or chemicals making the job safer?

• Are all employees following the safety procedures?

• Do your employees need more instruction and training on how to work safely?

• Are your employees actively identifying hazards and possible control measures?

• Are your employees raising health and safety concerns and reporting problems promptly?

• Are the frequency and severity of health and safety incidents reducing?

Resources

Hierarchy of Controls | NIOSH | CDC

Identifying Hazard Control Options: The Hierarchy of Controls (osha.gov)