Every year, thousands of workers suffer life-altering injuries—or worse, lose their lives—due to preventable workplace hazards. A worker handling a toxic chemical every day. They wear gloves and a mask, just as they were told, but after months of exposure, they start experiencing headaches and breathing issues. Many such incidents result from uncontrolled risks that could have been eliminated or reduced with the proper safety measures.
Too often, workplaces rely on protective equipment as the primary safety measure, expecting workers to manage risks instead of eliminating them.
But what if that toxic chemical could be replaced with a safer alternative? The hierarchy of Controls provides structured, proactive methods for workplace safety, ensuring that hazards are removed, replaced, or controlled at the highest possible level before resorting to personal protective equipment (PPE) as a last line of defense.
OSHA enforces safety standards that employers must follow to reduce workplace hazards. These standards cover machine safety, hazardous chemicals, fall protection, and personal protective equipment (PPE). OSHA also conducts workplace inspections, issues citations for violations, and provides training and resources to help businesses improve safety.
Safety isn’t about reacting to problems but creating a workplace where hazards are minimized. In this blog, we’ll explore each level of the Hierarchy of Controls, how to implement them effectively, and why proper workplace safety training is crucial to making these controls work.
Understanding Hierarchy of Controls
The Hierarchy of Controls is a structured strategy for minimizing or eliminating workplace hazards. It prioritizes control measures based on effectiveness, starting with the most effective (elimination) and ending with the least effective (personal protective equipment).
This hierarchy helps you manage risks systematically rather than relying solely on protective gear or administrative rules. By following this framework, you can identify the best solutions to reduce workplace dangers and improve safety.
| Hierarchy Level | Description |
| Elimination | Physically remove the hazard. |
| Substitution | Replace the hazard with a safer alternative. |
| Engineering Controls | Isolate people from the hazard using design solutions. |
| Administrative Controls | Change work procedures and policies to minimize exposure. |
| Personal Protective Equipment (PPE) | Use safety gear to reduce exposure to hazards. |
Each level provides a higher degree of safety than the one below it. The goal is to control hazards at the highest possible level before relying on PPE, which is the least effective because it depends on proper use and maintenance.
The Five Levels of the Safety Hierarchy of Controls
Understanding and applying the Hierarchy of Controls is essential for employers and employees. It provides a clear strategy for hazard management, leading to fewer workplace injuries, lower costs, and a stronger safety culture.
Elimination
Elimination removes a hazard so that it no longer exists in the workplace. This is the most effective way to prevent injuries and illnesses because it eliminates the source of the risk rather than trying to control or minimize exposure.
Examples of Elimination
- Automating hazardous tasks – Replacing manual handling of dangerous materials with robotic systems.
- Redesigning work processes – Changing production methods to eliminate toxic chemicals.
- Removing fall hazards – Designing workspaces so that elevated work is no longer required.
- Discontinuing dangerous equipment – Removing outdated machinery that poses a significant risk.
Challenges and Feasibility
Eliminating a hazard may require expensive new equipment, redesigned workflows, or infrastructure changes. Some risks are inherent to a job, making elimination impractical. For example, construction work always involves heights and moving machinery. Eliminating a hazard may slow production or require significant process changes, affecting productivity. Some industries lack viable alternatives to hazardous materials or processes.
When is Elimination Practical?
Elimination is most feasible when designing a new workplace or process; building safety into the design is easier than modifying an existing setup. If a process can be replaced with a safer method without reducing efficiency, elimination should be the first choice. Though expensive upfront, elimination often leads to lower injury rates, reduced liability, and increased productivity.
Employers should constantly evaluate whether elimination is possible before considering other control methods. If complete removal is not feasible, the next best option is substituting the hazard with a less dangerous alternative.
Substitution
Substitution involves replacing a hazardous material, process, or equipment with a safer alternative to reduce risk. Unlike elimination, which removes the hazard entirely, substitution allows the task to continue less dangerously.
Examples of Substitution
- Replacing toxic chemicals – Using water-based paints instead of solvent-based paints to reduce exposure to harmful fumes.
- Switching to safer equipment – Using electric forklifts instead of diesel-powered ones to eliminate exhaust emissions.
- Using less harmful cleaning agents – Replacing strong industrial solvents with biodegradable, non-toxic alternatives.
- Substituting manual processes with automation – Using power-assisted tools to reduce strain and repetitive motion injuries.
Considerations When Implementing Substitution
While substitution is a safer alternative, it must be carefully evaluated to ensure the new solution does not introduce unintended hazards. Consider the following factors:
Effectiveness of the Substitute
Does the new material or process perform as well as the original? Will it maintain productivity, efficiency, and quality?
Potential New Hazards
Does the substitute introduce different health or safety risks? For example, replacing one chemical with another may reduce toxicity but increase flammability. Switching to a new piece of equipment may reduce risk but create new operational challenges.
Cost and Feasibility
Is the alternative affordable and available? Does it require new training, modifications, or regulatory approvals? Will implementing the change disrupt workflow or require major process adjustments?
Long-Term Safety Benefits
Does the substitution eventually lead to a safer work environment? Will it reduce health risks, medical costs, and workplace incidents?
Best Practices for Implementing Substitution
Before making changes, conduct a thorough risk assessment. Involve workers and safety professionals to evaluate the impact of substitution. Monitor the new material or process to ensure it does not introduce unforeseen risks. Ensure compliance with OSHA regulations and industry standards.
Substitution is an effective way to reduce hazards when elimination is not possible. However, every alternative should be carefully tested and monitored to maintain workplace safety. If substitution is not viable, the next step in the hierarchy is engineering controls, which focus on isolating people from hazards.
Engineering Controls
Engineering controls involve physically modifying the workplace, equipment, or processes to isolate workers from hazards. Unlike elimination or substitution, which aim to remove hazards entirely, engineering controls focus on designing safety in the work environment to reduce exposure. Because they do not depend on human behavior, these solutions are often more reliable than administrative controls or personal protective equipment (PPE).
Examples of Engineering Controls
- Ventilation Systems for Airborne Contaminants: Installing local exhaust ventilation (LEV) systems to capture and remove harmful fumes, dust, or vapors at the source. Using fume hoods in laboratories to prevent chemical exposure.
- Machine Guarding to Prevent Injuries: Physical barriers or interlocking guards should be installed on machinery to keep workers from coming into contact with moving parts. Use light curtains or two-hand controls to prevent accidental activation of dangerous equipment.
- Soundproof Enclosures for Noise Protection: Loud machinery should be placed inside soundproof booths or enclosures to reduce workers’ exposure to noise. Sound-absorbing panels should also be installed in manufacturing areas to minimize workplace noise.
- Ergonomic Workstation Design: Using adjustable workstations, anti-fatigue mats, and mechanical lifting aids to reduce strain injuries and redesigning assembly lines to minimize awkward postures and repetitive motions.
Effectiveness of Engineering Controls
Engineering controls are among the most effective safety measures because they reduce hazards at the source rather than relying on workers to follow procedures or wear protective equipment. However, implementing them requires careful planning and consideration of costs, feasibility, and maintenance.
When to Use Engineering Controls
- When elimination or substitution is not feasible due to operational constraints.
- When a hazard is persistent or widespread, a long-term solution is required.
- When reducing worker exposure at the source is the most practical approach.
Engineering controls provide a proactive and effective way to enhance workplace safety. While they may involve higher upfront costs, they offer sustainable protection that does not rely on individual compliance. If engineering controls are not possible, the next step in the hierarchy is administrative controls, which focus on modifying work procedures to reduce risks.
Administrative Controls
Administrative controls involve changing work policies, procedures, and practices to reduce exposure to hazards. Instead of removing the hazard, these controls modify how people work to minimize risk. They are often used when elimination, substitution, or engineering controls are not feasible or require additional support.
Examples of Administrative Controls
- Rotating Workers to Limit Exposure Time: Reducing workers’ hours in hazardous environments by rotating shifts. Preventing prolonged exposure to extreme temperatures, noise, or toxic substances.
- Implementing Safety Training Programs and Warning Signage: Comprehensive training on hazard awareness, emergency procedures, and proper equipment use should be provided. Clear warning signs and labels should be placed near hazardous areas or materials to alert workers of potential dangers.
- Establishing Strict Lockout/Tagout (LOTO) Procedures: Implementing LOTO protocols to prevent accidental machine start-up during maintenance or repairs. Ensuring only authorized personnel can remove lockout devices to enhance safety.
- Enforcing Safe Work Practices: Regular safety meetings are required to discuss potential risks and preventive measures. Clear protocols must be established for handling hazardous materials, confined spaces, or electrical systems.
Limitations of Administrative Controls
Dependence on Human Behavior
Administrative controls rely on workers following rules and procedures, making them less reliable than engineering controls. Mistakes, complacency, or lack of adherence can lead to accidents despite safety measures.
Need for Continuous Monitoring and Enforcement
Employers must ensure ongoing supervision, audits, and reinforcement of safety policies. Without consistent enforcement, workers may ignore or forget procedures, reducing effectiveness.
Less Effective than Higher-Level Controls
Unlike elimination or engineering controls, administrative measures do not remove or isolate hazards. They only reduce the likelihood of exposure, meaning risks still exist.
When to Use Administrative Controls
- When elimination, substitution, or engineering controls are not feasible due to cost or operational limitations.
- As a secondary layer of protection to support higher-level safety measures.
- When hazards cannot be removed, exposure can be managed through better work practices.
While administrative controls play a crucial role in workplace safety, they should be combined with more effective hazard controls whenever possible. If risks remain, the final level of the safety hierarchy—Personal Protective Equipment (PPE)—serves as the last line of defense.
Personal Protective Equipment (PPE)
Personal Protective Equipment (PPE) consists of safety gear worn by workers to minimize exposure to workplace hazards. Unlike other control methods that remove or reduce hazards, PPE acts as a barrier between the worker and the danger but does not eliminate the risk.
Examples of PPE
- Head Protection: Hard hats to protect against falling objects and head injuries.
- Eye and Face Protection: Safety glasses or face shields to guard against flying debris, chemicals, or radiation.
- Respiratory Protection: Respirators filter harmful air dust, fumes, or chemicals.
- Hand Protection: Gloves to prevent cuts, burns, or exposure to harmful substances.
- Hearing Protection: Earplugs or earmuffs to reduce exposure to excessive noise levels.
- Foot Protection: Steel-toed boots to protect against falling objects and puncture hazards.
Why PPE is the Least Preferred Control Method
PPE is considered the last line of defense in the hierarchy of controls because it does not eliminate or reduce the hazard itself. Instead, it relies on workers correctly wearing and using the equipment to provide protection.
Unlike elimination or engineering controls, PPE only reduces exposure, meaning the risk still exists. Workers remain fully exposed to the hazard if PPE fails or is worn incorrectly. PPE may not be sufficiently protected in high-risk situations like working with toxic chemicals or extreme temperatures. Engineering controls or substitution are often necessary to reduce the hazard at its source.
When to Use PPE
- When no other controls are feasible, PPE is the only protection option.
- It is used alongside engineering or administrative controls as a secondary defense layer.
- When workers require temporary protection during emergencies or maintenance work.
Best Practices for PPE Use
- Train workers on proper PPE use, fit, and maintenance.
- Regularly inspect PPE to ensure it is in good condition.
- Provide PPE that fits properly and is comfortable to wear.
- Combine PPE with higher-level controls whenever possible for better protection.
While PPE is essential in many workplaces, it should never be the primary or only safety measure. Employers should always try to eliminate or reduce hazards at the source before relying on PPE as a protective solution.
The Role of Workplace Safety Training in Hazard Control
Workplace safety training is essential for preventing accidents, reducing injuries, and ensuring compliance with industry regulations. Even with strong hazard control measures, employees must be trained to recognize risks, follow safety protocols, and respond effectively in emergencies.
Collaborating with Gallagher Bassett, Safe T Professionals is essential in enhancing workplace safety through expert training and staffing solutions. Their onsite, in-person, and hybrid training courses, led by certified professionals, provide workers with hands-on knowledge and real-world applications for hazard prevention. This partnership strengthens businesses’ ability to implement the hierarchy of controls effectively and ensures that employees are well-prepared to handle workplace hazards.
By integrating comprehensive safety training with strong hazard control strategies, organizations can create a safer work environment, reduce incidents, and improve workforce readiness.
Protect Your Workforce and Upgrade Your Safety Protocols With Safe T Professionals
At Safe T Professionals, we are dedicated to elevating safety standards through our expert consulting and staffing services. By proactively addressing and preventing safety issues and equipping your workforce with the necessary knowledge and tools, we help create a safer work environment.
Partner with Safe T Professionals to enhance your company’s safety protocols and ensure compliance with industry standards. Whether you are looking to fill safety-specific roles or need expert consultation to mitigate workplace hazards, we are here to help.
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