Key Takeaways
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Hazard control is the process of identifying and reducing risks in the workplace using a structured approach.
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OSHA follows a Hierarchy of Controls system to effectively manage hazard prevention and control.
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The OSHA Hierarchy of Controls focuses on elimination, substitution, engineering controls, administrative controls, and PPE to manage hazards effectively.
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OSHA prioritizes engineering controls over PPE because they address hazards at the source rather than relying on individual behavior.
What Is Hazard Control?
Hazard control is the process of identifying, assessing, and eliminating or minimizing risks in the workplace to protect employees from injuries, illnesses, and accidents. It is a structured approach that aims to reduce exposure to occupational hazards by implementing control methods that either remove the risk entirely or manage it effectively.
These occupational hazards can be anything that poses a potential threat to safety or health, such as hazardous chemicals, loud machinery, electrical dangers, or even biological health crises.
OSHA’s Approach to Hazard Prevention and Control
The Occupational Safety and Health Administration (OSHA) follows a structured approach to control and prevent hazards, ensuring that workplaces minimize risks and protect workers from occupational hazards. This approach follows the “OSHA Hierarchy of Controls,” a system that categorizes control strategies into five levels, ranked from most effective to least effective:
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Elimination
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Substitution
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Engineering Controls
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Administrative Controls
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Personal Protective Equipment (PPE)
The OSHA Hierarchy of Controls prioritizes eliminating hazards at their source and reducing exposure. But, what happens when eliminating hazards is not feasible?
Understanding OSHA’s Three Lines of Defense
When hazard elimination is not possible, the next best strategy is to follow OSHA’s Three Lines of Defense within the hierarchy, which prioritizes engineering controls, administrative controls, and PPE in that order. It is a layered approach that focuses on the control measures that protect workers from existing hazards. Let’s take a closer look:
Engineering Controls
Engineering controls are considered the most effective method among OSHA’s Three Lines of Defense. They involve modifying equipment, processes, or the work environment to reduce or isolate workers from hazards. These hazard control measures do not rely on human behavior and provide long-term protection. However, engineering controls may be costly to implement and may require ongoing maintenance to ensure their continued effectiveness.
Engineering Controls Examples:
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Automate hazardous tasks to reduce direct worker exposure.
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Improve ventilation systems to control airborne contaminants instead of relying on respirators.
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Install machine guarding to prevent contact with moving parts.
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Use soundproof barriers to reduce hearing protection dependency.
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Redesign workstations for better ergonomics, minimizing repetitive stress injuries.
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To implement effective OSHA engineering controls, start by identifying hazards that can be physically controlled. Collaborate with engineers or safety professionals to evaluate existing controls and determine design modifications that reduce risks at the source. Once selected controls are in place, provide workers with proper training to use the new systems safely and effectively.
Administrative Controls
Administrative controls help reduce the duration, frequency, and severity of exposure to hazards through employee training, safety policies, and procedures. It is recognized as necessary but less reliable than engineering controls because they depend on human behavior. If workers forget, ignore, or are unaware of safety work practices, hazards remain a risk.
While not as effective as OSHA engineering controls, administrative controls are flexible, relatively low cost, and crucial when modifying physical environments is not feasible or insufficient.
Administrative Controls Examples:
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Job rotation schedules to limit time in hazardous areas.
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Mandatory safety training to reinforce best practices.
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Warning signs and labels to alert workers of risks.
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Enforcing break schedules to prevent fatigue-related accidents.
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Clear safety programs and procedures for handling hazardous materials.
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To implement administrative controls OSHA, organizations should begin by identifying risks, evaluating controls, and establishing policies that address security, safety, and compliance requirements. Work with safety professionals to develop clear policies and provide thorough training. Leadership support and a culture of compliance are essential to ensuring these selected controls are followed effectively across the organization.
Personal Protective Equipment (PPE)
Personal Protective Equipment, or PPE, is the last line of defense in OSHA’s Three Lines of Defense framework. It is a backup measure when engineering and administrative controls can’t fully eliminate the risk. It does not remove the hazard, but it reduces exposure severity.
Personal Protective Equipment (PPE) Examples:
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Safety gloves for handling hazardous chemicals.
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Safety glasses for protecting eyes from flying debris, chemical splashes, dust, or radiation.
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Respirators for workers in environments with airborne contaminants.
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Hard hats and steel-toed boots in construction zones.
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For maximum efficiency, PPE engineering controls should fit properly to provide effective protection, so workers must be trained on how to wear and use it correctly. Regular maintenance and timely replacement help prevent equipment worn and keep protection reliable. PPE should always be used alongside other control measures rather than as the only safeguard against hazards.
Why Does OSHA Prioritize Engineering Controls Over PPE?
We often think that PPE is the first line of defense in hazard control, but this is a misunderstanding of workplace safety principles. In reality, PPE is considered the last line of defense in the OSHA Hierarchy of Controls.
OSHA prioritizes engineering controls over PPE because they eliminate or reduce hazards at the source, whereas PPE only provides individual protection and depends on proper use. Engineering controls offer long-term, built-in solutions that do not rely on worker behavior, making them more dependable and effective in controlling unsafe working conditions.
For employers, this means engineering controls should always be the first consideration when mitigating occupational hazards, rather than relying on PPE as the primary form of protection. Safety experts recommend the following approach:
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Before issuing PPE, consider solutions such as ventilation, machine guards, soundproofing, and ergonomic design.
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Implement scheduling adjustments, safety training, and job rotation only when engineering solutions are not enough.
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PPE should be a last resort when other controls are impractical or insufficient. Employers should also ensure PPE is properly maintained, fitted, and used correctly.
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Workplace risks evolve, so employers must routinely review hazard control methods and update them as needed.
What Is the Importance of Hazard Control?
The concept of hazard control aligns with the safety pyramid, which shows that minor incidents often precede serious injuries. By applying higher-level controls, employers reduce the likelihood of small hazards leading to major accidents. This reinforces why OSHA’s Three Lines of Defense prioritizes engineering controls over PPE—controlling hazards at the source lowers both minor and severe incidents, creating a safer workplace overall.
A well-implemented hazard control strategy not only prevents accidents but also improves productivity, reduces costs related to injuries, and helps organizations comply with OSHA regulations.
Hazard Prevention and Control FAQs
What type of control would describe training, inspection, and housekeeping?
These are administrative controls, which focus on reducing risk through policies, procedures, and workplace practices rather than eliminating the hazard itself. They help manage exposure by improving worker awareness, enforcing safe behaviors, and maintaining a clean and organized work environment.
What is the best hazard control?
The most effective hazard control is elimination, which removes the hazard entirely from the workplace. If elimination is not possible, engineering controls are the next best option, as they reduce risk at the source without relying on worker actions.
Where does PPE fall on the Hierarchy of Controls OSHA?
PPE is the last level in the OSHA Hierarchy of Controls, meaning it should only be used when hazards cannot be eliminated or controlled through engineering or administrative measures. It provides individual protection but does not remove or reduce the hazard itself.
What is the hazard control plan?
A hazard control plan outlines how an organization identifies, assesses, and addresses workplace hazards using the hierarchy of controls. It includes strategies for eliminating risks, implementing engineering and administrative controls, and providing PPE when necessary.
What is the first choice for how to reduce or eliminate a hazard?
The first choice is elimination, which removes the hazard entirely, making the workplace safer without needing further controls. If elimination isn’t feasible, substitution—replacing a hazardous process or material with a safer alternative—is the next best option.