Hierarchy of Control: How to Manage Workplace Hazards

Workplace hazards can come in many forms, from hazardous chemicals and moving machinery to manual handling, electrical risks, slips and falls. Identifying these hazards is an important first step, but effective workplace safety depends on what you do to control the risks they create.

The Hierarchy of Control is a widely used framework for managing workplace hazards. It ranks different control measures from the most effective way of reducing risk through to measures that provide protection but rely more heavily on worker behaviour.

For Australian workplaces, the hierarchy of control forms an important part of the process for identifying, assessing and controlling WHS risks.

What Is the Hierarchy of Control?

The Hierarchy of Control is a system used to determine the most effective way to eliminate or minimise workplace risks.

The controls are ranked from the highest level of protection and reliability to the lowest:

1. Elimination
2. Substitution
3. Isolation
4. Engineering Controls
5. Administrative Controls
6. Personal Protective Equipment (PPE)

The aim is to work from the top of the hierarchy wherever reasonably practicable. Higher-level controls generally address the hazard at its source, while lower-level controls rely more heavily on workers following procedures or using equipment correctly.

1. Elimination – Remove the Hazard

Elimination is the most effective control because it removes the hazard completely.

This could involve removing a hazardous task, process, material or piece of equipment from the workplace.

Examples include:

• Removing an unnecessary hazardous chemical from a workplace
• Eliminating work at height by completing the task at ground level
• Removing damaged or unsafe equipment from service
• Redesigning a process so workers no longer need to interact with a hazard

2. Substitution – Replace the Hazard

If eliminating a hazard is not reasonably practicable, the next step is to consider whether it can be replaced with something safer.

Substitution involves replacing a hazardous substance, process or piece of equipment with an alternative that presents a lower risk.

Examples include:

• Replacing a highly hazardous chemical with a less hazardous alternative
• Using a water-based product instead of a solvent-based product where suitable
• Replacing a manual process with a safer alternative

3. Isolation – Separate People From the Hazard

Isolation involves physically separating workers from the hazard.

This can be particularly useful where a hazardous process, substance or piece of equipment cannot be removed.

Examples include:

• Installing barriers around moving machinery
• Restricting access to hazardous areas
• Separating pedestrians from forklifts and other mobile equipment
• Using enclosed areas or storage facilities for hazardous substances

4. Engineering Controls – Make the Workplace Safer

Engineering controls involve physically changing equipment, machinery or the workplace to reduce exposure to a hazard.

Unlike administrative controls, engineering controls do not rely solely on workers remembering to follow a procedure.

Examples include:

• Machine guarding
• Mechanical lifting equipment
• Local exhaust ventilation
• Safety barriers and guarding
• Spill containment systems
• Interlocking safety systems
• Emergency eyewash and safety shower equipment

5. Administrative Controls – Change the Way Work Is Done

Administrative controls involve changing work practices, procedures or systems to reduce exposure to a hazard.

These controls can include:

• Safe work procedures
• Training and instruction
• Workplace inspections
• Warning and safety signs
• Job rotation or scheduling
• Restricted access procedures
• Maintenance schedules
• Emergency response procedures

Administrative controls are an important part of workplace safety, but they generally rely on people following instructions and procedures correctly. 

6. Personal Protective Equipment – Protect the Worker

Personal Protective Equipment (PPE) is used to protect workers from hazards that remain after other control measures have been considered.

Depending on the workplace and task, PPE can include:

• Safety glasses and goggles
• Protective gloves
• Respiratory protection
• Hearing protection
• Safety footwear
• High-visibility clothing
• Hard hats
• Protective clothing

PPE is an important part of many workplace safety programs, but it should not automatically be the first control considered.

Using More Than One Control

The Hierarchy of Control does not mean that only one control measure can be used.

In many workplaces, the most effective approach is to use a combination of controls.

For example, a workplace storing hazardous chemicals may use:

Engineering: Appropriate chemical storage cabinets and spill containment
Administrative: Chemical handling procedures and worker training
PPE: Gloves, eye protection and other required protective equipment

Using multiple controls can provide additional protection if one control becomes ineffective or is not followed correctly.

The Hierarchy of Control in Practice

Consider a workplace where employees are exposed to a chemical spill risk.

Instead of relying only on PPE, a business could work through the hierarchy:

• Eliminate: Remove the chemical if it is no longer required.
• Substitute: Replace it with a less hazardous alternative where suitable.
• Isolate: Restrict access to the chemical storage area.
• Engineer: Use appropriate chemical storage cabinets, spill containment and other physical controls.
• Administrate: Introduce handling procedures, training, inspections and emergency response plans.
• PPE: Provide appropriate gloves, eye protection and protective clothing for workers handling the chemical.

This layered approach helps address the hazard from multiple angles rather than relying on workers to protect themselves through PPE alone.

Why Is the Hierarchy of Control Important?

A strong workplace safety program starts by asking "How can we remove or reduce the hazard?", rather than simply asking "What PPE should workers wear?"

The hierarchy helps businesses:

• Identify the most effective ways to control hazards
• Reduce worker exposure to dangerous situations
• Select appropriate safety equipment and procedures
• Build safer work environments
• Support ongoing WHS risk management
• Review whether existing controls are still effective

Safe Work Australia recommends a four-step risk management process: identify hazards, assess risks, control risks and review control measures. Consultation with workers should occur throughout the process.

Reviewing Your Workplace Controls

Workplace hazards can change as equipment, processes, chemicals and working conditions change. Controls should therefore be reviewed regularly to make sure they continue to work as intended.

Businesses should consider reviewing their controls when:

• A new chemical, machine or process is introduced
• There has been an incident or near miss
• Work practices change
• Existing equipment becomes damaged or outdated
• Workers identify a new hazard
• A control measure is found to be ineffective

Regular review helps ensure that workplace safety measures remain appropriate for the risks workers are actually exposed to.

Use Titan Safety to Protect Your Workplace With the Right Safety Equipment

From eliminating a hazard through to using PPE, each level has an important role to play. The right solution will depend on the hazard, the workplace and the specific circumstances involved.

Titan Safety supplies a range of workplace safety equipment designed to help businesses manage and minimise workplace risks, including dangerous goods storage, spill containment, safety showers and eyewash equipment, traffic safety products and workplace safety equipment.

Explore the Titan Safety range to find practical safety solutions for your workplace.