A Guide to the Hierarchy of Controls

What is the Hierarchy of Controls?

The Hierarchy of Controls arranges risk control measures into levels based on how safe and effective they are. It’s a framework that helps prioritize controls that eliminate work hazards before turning to measures that only mitigate safety concerns. The hierarchy encourages organizations to aim for zero hazard exposure for workers, rather than relying mainly on behavior and protective gear.

The Five Levels of the Hierarchy

The hierarchy of control measures is an order of stages that can be considered as lines of defense. The risk control levels are as follows:

1. Elimination

Elimination is the approach of removing hazards entirely from the environment or workplace. It’s considered the highest level of protection and the most effective control measure in the hierarchy.

Examples:

• Change cleaning processes to remove the use of chemicals that could cause severe irritation to the skin.

• Place frequently used materials at floor level, so teams don’t have to use ladders as often.

• Install clean-in-place systems to phase out entry into tight tanks.

2. Substitution

This measure focuses on replacing hazardous materials or processes with safer options. It’s the next level of defense if eliminating the hazard isn’t possible.

Examples:

• Replace solvent-based paint with water-based paint.

• Use electrical equipment that produces sound with lower frequencies and volume.

• Swap internal combustion forklifts with electric lift trucks to reduce fumes.

3. Engineering controls

Engineering controls place physical barriers and systems to keep workers away from hazards. Doing so minimizes the risks of health issues and injuries.

Examples:

• Install fixed guards on machines.

• Set up exhaust ventilation and fume hoods.

• Put up physical barriers to separate pedestrian lanes and moving vehicle lanes.

4. Administrative controls

This control measure involves implementing procedures, requirements, and policies for working safely under anticipated conditions. It helps control and change how employees work and their behavior towards risks.

Examples:

• Require access control to facilities and equipment with significant hazards.

• Create control of work systems to limit access to higher-risk tasks.

• Schedule outdoor work early in the day.

• Safety signs and warnings

5. Personal Protective Equipment (PPE)

PPE refers to the various gear that workers wear to reduce exposure and risks of injury. This is the lowest level of protection and the least reliable control.

Examples:

• Use respirators when surrounded by materials that produce dangerous dust.

• Wear safety goggles and gloves when conducting hot work.

• Fit earplugs when working around loud machines.

Why Use the Hierarchy of Controls?

The hierarchy of controls supports strong and sustainable workplace safety. It gives organizations a template for minimizing hazards and preventing incidents and fatalities. This is because of the following outcomes the framework delivers:

• Finds the most effective risk controls: It drives organizations to focus on removing hazards or blocking exposure, rather than asking employees to work around them.

• Promotes logical decision-making: The hierarchy provides a clear process that considers all possible hazards, work issues, and safety measures.

• Creates long-term safety solutions: Prioritizing high-level controls can provide retainable or even permanent hazard prevention systems.

• Makes resource allocation efficient: Investing in high-level measures saves on repairs, replacement, and injury costs.

• Strengthens organizational safety culture: The framework prioritizes safety equally with productivity, improving worker trust and engagement.

What Standards Reference the Hierarchy?

The hierarchy of controls remains central to workplace safety agencies and regulatory bodies, including the following:

• National Institute for Occupational Safety and Health: The agency includes the hierarchy as a strategy in the national Prevention through Design (PtD) initiative.

• Occupational Safety and Health Administration: The federal organization highlights the framework as recommended practice for safety and health programs.

• National Fire Protection Association: Their 70E: Standard for Electrical Safety in the Workplace outlines the control hierarchy for risk assessments to avoid injuries and fatalities due to shock, electrocution, arc flash, and arc blast.

• National Safety Council: As a helpful reference , the council recommends the hierarchy of controls as a safety tool to its members.

Byblos Construction digitized safety checklists, compliance checks, and risk assessments with SafetyCulture, letting teams quickly notify leaders of risks for faster action and fewer blind spots. This improved risk management, communication, and visibility for safer job sites.

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How to Apply It in Practice

Applying the hierarchy of controls involves using a step-by-step approach that follows the funnel from top to bottom. Below is a quick guide to practicing this framework:

Identify and assess risks clearly

Start by specifying the processes, environments, or equipment that create hazards, as well as the extent of injuries they can cause. This creates a clear understanding of risk levels.

Choose or combine the highest-level risk controls

Whenever possible, prioritize elimination and substitution as risk management measures. However, when those aren’t reasonable, move to the highest available measure by starting with engineering controls, then work down from there.

Induct workers and manage change

Adoption of risk controls is easier when teams understand why the measure is in place and how to use it properly. Make sure to address resistance, concerns, and adjustments related to changes.

Monitor the effectiveness of controls and improve

Regularly inspect and audit risk controls, focusing on risk reduction and worker compliance with standards. At the same time, remain alert for any incidents and near misses that may point to gaps in the controls.