- Hierarchy of Controls in Practice
- What Is the Hierarchy of Controls?
- Hierarchy of Controls in Practice: Real-World Application
- Visual Summary of the Hierarchy of Controls
- Common Missteps in Applying the Hierarchy of Controls
- Integration into Safety Programs
- Digital Tools to Support Control Implementation
- Start at the Top of the Pyramid
Hierarchy of Controls in Practice
Hierarchy of Controls in Practice is the application of a proven framework used to reduce or eliminate workplace hazards. While many safety professionals know the concept, the real challenge lies in applying it effectively on job sites and in dynamic work environments.
Developed by the National Institute for Occupational Safety and Health (NIOSH), this hierarchy ranks hazard control methods from most to least effective.
Implementing it correctly helps reduce risks systematically, promoting safer, healthier workplaces.
What Is the Hierarchy of Controls?
The Hierarchy of Controls outlines five levels of intervention:
- Elimination – Physically removing the hazard.
- Substitution – Replacing the hazard with a safer option.
- Engineering Controls – Isolating people from the hazard.
- Administrative Controls – Changing how people work.
- Personal Protective Equipment (PPE) – Protecting the worker with gear.
The higher up the pyramid, the more effective and reliable the control.
Hierarchy of Controls in Practice: Real-World Application
Understanding the theory is one thing—putting it into action is another. Here’s how to apply the hierarchy in everyday workplace situations.
1. Elimination: The Gold Standard
Example: Instead of having workers climb ladders to replace lightbulbs, install long-lasting LED fixtures that require replacement only every 10 years.
Why It Works: By eliminating the task, you eliminate all associated risks—falls, fatigue, electrical hazards, etc.
Tip: Elimination often occurs during design or planning phases. Encourage safety involvement in project planning and procurement.
2. Substitution: Safer Alternatives
Example: Use water-based paints instead of solvent-based ones to reduce volatile organic compound (VOC) exposure.
Why It Works: Substitution minimizes hazard severity while maintaining function.
Tip: Always evaluate new materials for hidden hazards before substituting. Some replacements may introduce different risks.
3. Engineering Controls: Isolate the Hazard
Example: Use guardrails on elevated platforms or install machine guards on cutting equipment.
Why It Works: Engineering controls physically separate workers from the hazard. They don’t rely on human behavior and reduce the potential for error.
Tip: Design controls to be fail-safe and require minimal user input.
4. Administrative Controls: Modify Human Behavior
Example: Rotate workers every two hours in hot environments to reduce heat stress or implement permit-to-work systems in confined spaces.
Why It Works: These controls influence behavior and scheduling, reducing exposure duration or frequency.
Tip: Combine administrative measures with higher-tier controls for best results.
5. Personal Protective Equipment (PPE): The Last Line of Defense
Example: Provide respiratory masks when working with dust or fumes, or gloves when handling chemicals.
Why It Works: PPE is essential where higher-level controls aren’t feasible but is considered the least reliable due to the dependency on proper use.
Tip: Train workers thoroughly on correct PPE usage, maintenance, and limitations. Use CSA Z94.4 as a guideline (DoFollow).
Visual Summary of the Hierarchy of Controls
| Level | Description | Effectiveness | Example |
|---|---|---|---|
| Elimination | Remove the hazard | Highest | Automate high-risk task |
| Substitution | Replace with safer option | High | Water-based cleaners |
| Engineering | Isolate people | Medium-High | Machine guards |
| Administrative | Change the way people work | Medium | Safety training |
| PPE | Wear protective gear | Lowest | Hard hats, gloves |
Common Missteps in Applying the Hierarchy of Controls
- Relying solely on PPE: Too many workplaces default to PPE without considering upstream solutions.
- Skipping hazard assessment: Without proper risk evaluation, controls may target the wrong issues.
- Lack of follow-up: Controls must be evaluated over time to ensure ongoing effectiveness.
A well-rounded system includes training, feedback loops, and worker involvement in hazard control discussions.
Integration into Safety Programs
The Hierarchy of Controls in Practice should be embedded into:
- Job Hazard Analyses (JHA)
- Safety Management Systems (SMS)
- Safety Audit Checklists
- Engineering Project Reviews
- Daily Safety Toolbox Talks
Embedding the hierarchy into routine safety workflows ensures that decisions aren’t just reactive but strategically preventive.
Digital Tools to Support Control Implementation
- iAuditor by SafetyCulture – For assigning controls post-inspection.
- EcoOnline – For chemical substitution tracking.
- SiteDocs – For PPE compliance and task control documentation.
Digital tools make tracking the success of controls easier, ensuring real-time adjustments and audit readiness.
Start at the Top of the Pyramid
The Hierarchy of Controls in Practice is more than a chart—it’s a powerful strategy to eliminate, reduce, and manage hazards effectively. It provides a structured approach to making workplaces genuinely safer, not just compliant on paper.
Empower your team to think beyond PPE and design out risk at the source.
🔹 1. What is the Hierarchy of Controls?
Answer:
The Hierarchy of Controls is a system used to minimize or eliminate exposure to hazards. It ranks control strategies from most effective to least: Elimination, Substitution, Engineering Controls, Administrative Controls, and Personal Protective Equipment (PPE).
🔹 2. Why is Elimination considered the most effective control?
Answer:
Elimination removes the hazard completely, which means there is no risk of exposure. For example, removing a dangerous machine from use eliminates all risks associated with it.
🔹 3. Can you give an example of Substitution?
Answer:
Yes. Replacing a solvent-based paint with a water-based paint to reduce harmful fumes is a classic example of substitution.
🔹 4. How do Engineering Controls differ from Administrative Controls?
Answer:
Engineering Controls physically isolate people from the hazard (e.g., machine guarding, ventilation systems), while Administrative Controls change how people work (e.g., training, shift rotation).
🔹 5. Why is PPE the least preferred method of control?
Answer:
PPE is the last line of defense because it doesn’t eliminate the hazard—it only reduces exposure. It relies heavily on worker behavior and can fail due to misuse, damage, or fatigue.
🔹 6. When should the Hierarchy of Controls be applied?
Answer:
It should be used during:
- Job Hazard Analysis (JHA)
- Incident investigations
- New task planning
- Design or procurement stages
🔹 7. What makes Engineering Controls more reliable than PPE?
Answer:
Engineering controls don’t rely on human behavior. For example, a guardrail will protect workers regardless of training or vigilance, whereas PPE requires correct and consistent use.
🔹 8. Are multiple controls ever used together?
Answer:
Yes. Often, workplaces use a combination of controls for layered protection. For example, a noisy machine might be enclosed (engineering), with restricted access (admin), and require hearing protection (PPE).
🔹 9. Who is responsible for implementing the Hierarchy of Controls?
Answer:
Supervisors, safety professionals, and employers are primarily responsible, but workers must participate in identifying hazards and applying the controls effectively.
🔹 10. How can you ensure controls remain effective over time?
Answer:
By conducting regular safety audits, inspections, and reviewing incident reports, workplaces can evaluate whether controls are still working or need updating.