Hierarchy of Control: 6 Steps to Workplace Safety
Ensuring workplace safety is a top priority for every organisation. One of the most effective frameworks for managing risks is the Hierarchy of Control. This system provides a structured, step-by-step approach to identifying hazards, evaluating risks, and applying control measures. By following the hierarchy, businesses can create safer environments, comply with WHS/OHS regulations, and protect workers from harm.
What is the Hierarchy of Control?
The Hierarchy of Control is a systematic framework used in workplace health and safety (WHS) to manage risks. It ranks control measures from most effective to least effective so organisations can prioritise solutions that remove or reduce hazards.
Visualised as a pyramid, the strongest measures (like eliminating a hazard) sit at the top, while less reliable measures (like PPE) sit at the bottom. In practice, companies often combine multiple steps for the best protection.
Why is the Hierarchy of Control Important?
The hierarchy exists to give organisations a clear roadmap for hazard management. Instead of relying on short-term fixes, it encourages businesses to start with the most effective methods first.
Key benefits include:
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Compliance with WHS and OHS legislation.
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Reduced workplace incidents, injuries, and downtime.
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A proactive safety culture where risks are managed before accidents occur.
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Better resource allocation by targeting high-impact controls.
The 6 Steps of the Hierarchy of Control
1. Elimination
Remove the hazard completely so it no longer poses a risk. This is the most effective form of risk control.
Example:
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(Warehousing): Redesigning workflows to remove the need for a high-risk machine.
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(Construction): Stopping the use of a hazardous chemical altogether by redesigning processes.
2. Substitution
Replace the hazard with something safer. While not as strong as elimination, it still significantly reduces risk.
Example:
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(Laboratory): Replacing a toxic solvent with a safer, less harmful chemical.
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(Healthcare): Switching from glass to plastic equipment to reduce sharps injuries.
3. Engineering Controls
Design safer systems or modify equipment to minimise exposure. These measures physically separate workers from hazards.
Example:
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(Manufacturing) Installing dust extraction systems to remove airborne particles.
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(Logistics): Adding guards to forklifts and conveyor systems to prevent injuries.
4. Administrative Controls
Change the way people work through training, policies, and scheduling. These rely on procedures rather than physical changes.
Example:
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(Warehouse): Rotating staff to reduce repetitive strain injuries from manual handling.
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(Construction): Introducing a “permit to work” system for high-risk activities.
5. Personal Protective Equipment (PPE)
Provide workers with protective gear such as gloves, helmets, goggles, or respirators. PPE is considered the least effective control because it depends on correct use and maintenance.
Example:
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(Construction): Helmets and steel-toed boots for protection against falling debris.
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(Healthcare): Gloves and masks when handling infectious materials.
6. Isolation
Separate people from the hazard by creating barriers or restricted access zones.
Example:
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(Manufacturing) Enclosing high-temperature machinery with heat-resistant barriers.
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(Logistics): Designating “pedestrian-free zones” around forklift traffic.
What is the First Step of the Hierarchy of Control?
The first step is Elimination. If a hazard can be completely removed, the risk is eliminated too. While not always practical, it should be the first option considered in every risk assessment.
Practical Examples of the Hierarchy in Action:
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Elimination: A factory redesigns its process to avoid using a toxic chemical.
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Substitution: A warehouse replaces solvent-based cleaners with water-based alternatives.
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Engineering: A logistics centre installs automated conveyor systems to reduce manual lifting.
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Administrative: A hospital introduces strict infection-control training for staff.
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PPE: A construction crew is issued hard hats, gloves, and eye protection.
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Isolation: A mining company restricts access to blasting zones until the area is cleared.
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Conclusion
The Hierarchy of Control provides a proven, step-by-step method for reducing workplace risks. By prioritising elimination and substitution before relying on PPE, organisations can protect workers, comply with WHS laws, and foster a culture of safety.
Want to put the hierarchy of control into action in your business?
Contact OneSystem’s safety team today and see how we can help you streamline risk management.
FAQs
Because it relies on workers wearing equipment correctly every time. Human error or equipment failure can reduce its effectiveness.
Yes. The best safety outcomes often come from combining controls, such as engineering solutions with PPE.
In Australia, WHS and OHS regulations reference the hierarchy of control as the preferred risk management method.
