What is a hazard control program?

A hazard control program consists of all steps necessary to protect workers from
exposure to a substance or system, the training and the procedures required to monitor
worker exposure and their health to hazards such as chemicals, materials or substance,
or other types of hazards such as noise and vibration. A written workplace hazard
control program should outline which methods are being used to control the exposure
and how these controls will be monitored for effectiveness.

How do I know what kind of control is needed?

Selecting an appropriate control is not always easy. It often involves doing a risk
assessment to evaluate and prioritize the hazards and risks. In addition, both "normal"
and any potential or unusual situations must be studied. Each program should be
specially designed to suit the needs of the individual workplace. Hence, no two
programs will be exactly alike.
Choosing a control method may involve:

 Evaluating and selecting temporary and permanent controls.

 Implementing temporary measures until permanent (engineering) controls can
be put in place.
 Implementing permanent controls when reasonably practicable.

For example, in the case of a noise hazard, temporary measures might require workers
to use hearing protection. Long term, permanent controls might use engineering
methods to remove or isolate the noise source.

What are the main ways to control a hazard?

The main ways to control a hazard include:

 Elimination (including substitution): remove the hazard from the workplace, or

substitute (replace) hazardous materials or machines with less hazardous ones.
 Engineering Controls: includes designs or modifications to plants, equipment,
ventilation systems, and processes that reduce the source of exposure.
 Administrative Controls: controls that alter the way the work is done, including
timing of work, policies and other rules, and work practices such as standards and
operating procedures (including training, housekeeping, and equipment
maintenance, and personal hygiene practices).
 Personal Protective Equipment: equipment worn by individuals to reduce
exposure such as contact with chemicals or exposure to noise.

Where are controls used?

Controls are usually placed:

1. At the source (where the hazard "comes from").

 2. Along the path (where the hazard "travels").
3. At the worker.

Control at the source and control along the path are sometimes also known as
engineering controls (see below for more details)

Elimination

Elimination is the process of removing the hazard from the workplace. It is the most
effective way to control a risk because the hazard is no longer present. It is the
preferred way to control a hazard and should be used whenever possible.
The elimination stage of the hierarchy of controls is by far the most effective, because
it removes the risk of incident altogether.

Many companies still struggle with the elimination step, since they only look at the
initial costs of making a fundamental change to the operation of the business. Once
they discover the long-term savings, both in operational and workers compensation
terms, elimination becomes a more viable directive.

 Elimination – Physically remove the hazard

 Substitution – Replace the hazard
 Engineering controls – Isolate people from the hazard
 Administrative controls – Change the way people work
 Personal protective equipment– Protect the worker with PPE

Collaborate to eliminate

NIOSH states that elimination and substitution is often more difficult to enact after
work has begun. The goal of substitution is to replace a hazardous product or process
with a safer one. Examples include using non-toxic or less toxic chemicals and
upgrading aging machinery with newer equipment.

‘Make the work easier’

NIOSH identifies numerous hazards for which engineering controls can be effective.
They include noise, falls, silica, aerosols, asphalt fumes, formaldehyde, hazardous
drugs, lead, asbestos, carbon monoxide and nitrous oxide.

One example the agency cites involves establishing local exhaust ventilation to isolate
and remove airborne emissions. Another is using machine guarding to protect
operators.

“Well-designed engineering controls can be highly effective in protecting workers

and will typically be independent of worker interactions,” NIOSH states. “They
typically do not interfere with worker productivity or personal comfort, and make the
work easier to perform rather than more difficult.”

Substitution

Example: Acme Farms sees many employees suffer health problems due to the use of
pesticides with DDT. The farm substitutes an organic pesticide, and the health issues
go away.

Much like elimination, substitution seeks to remove the causes of accidents before an
incident occurs. The procedure for substitution follows the same guidelines as
elimination, but this time the company examines products and chemicals instead of
actions.

Substitution meets some resistance from companies for two reasons, First, safer
alternatives are sometimes more expensive than their harmful alternatives. Second,
they substitute one product with another that causes the same or similar safety issues.
Substitution is a process that requires an investment of time and energy to sample
several different alternatives before making a switch.

Substitution occurs when a new chemical or substance that is less hazardous is used
instead of another chemical. It is sometimes grouped with elimination because, in
effect, you are removing the first substance or hazard from the workplace. The goal,
obviously, is to choose a new chemical that is less hazardous than the original.
The table below provides some examples:

Instead Of: Consider:

carbon tetrachloride (causes liver damage, 1,1,1-trichloroethane,
cancer) dichloromethane
benzene (causes cancer) toluene, cyclohexane, ketones
pesticides (causes various effects on body) "natural" pesticides such as
pyrethrins
organic solvents (causes various effects on body) water-detergent solutions
leaded glazes, paints, pigments (causes various versions that do not contain lead
effects on body)
sandstone grinding wheels (causes severe synthetic grinding wheels such as
respiratory illness due to silica) aluminium oxide

Remember, however, that you need to make sure the substitute chemical or substance
is not causing any harmful effects, and to control and monitor exposures to make sure
that the replacement chemical or substance is below occupational exposure limits.
Another type of substitution includes using the same chemical but to use it in a
different form. For example, a dry, dusty powder may be a significant inhalation
hazard but if this material can be purchased and used as pellets or crystals, there may
be less dust in the air and therefore less exposure.

Figure 3

Remember!
When substituting, be very careful that one hazard is not being traded for another.
Before deciding to replace a chemical/substance with another, consider all the
implications and potential risks of the new material.
Substitution may also include using a machine that requires less energy, or lifting
items with less weight.
Engineering

Example: Southwest Manufacturing’s employees complain of respiratory and allergy

issues from airborne particles on the factory floor. The company installs a vent hood
to circulate air and reduce air pollutants inside the factory.

Administrative controls limit exposure to hazards by adjusting work tasks or

schedules. According to OSHA, examples include:

 Limiting the time a worker is exposed to a hazard

 Creating written operating procedures
 Installing alarms, signs and warnings
 Using a buddy system

Engineering controls are a compromise tactic between eliminating the problems and
leaving them completely unaddressed. Companies use engineering controls to
physically separate employees from harmful machines or dangerous working
conditions. The company can do so through removing the hazard from the
environment or creating a barrier.

Most engineering controls are expensive from the outset, and can lead to further
problems in the future. Since the company never addressed the root cause of the
hazard, if the control fails, employees may still get injured.

What are examples of engineering controls?

Engineering controls are methods that are built into the design of a plant, equipment
or process to minimize the hazard. Engineering controls are a very reliable way to
control worker exposures as long as the controls are designed, used and maintained
properly. The basic types of engineering controls are:

 Process control.
 Enclosure and/or isolation of emission source.
 Ventilation.

Process Control

Process control involves changing the way a job activity or process is done to reduce
the risk. Monitoring should be done before and as well as after the change is
implemented to make sure the changes did, in fact, control the hazard.
Examples of process changes include to:

 Use wet methods rather than dry when drilling or grinding. "Wet method"
means that water is sprayed over a dusty surface to keep dust levels down or
material is mixed with water to prevent dust from being created.
  Use an appropriate vacuum or "wet method" instead of dry sweeping (e.g. with
a broom) to control dust and reduce the inhalation hazard.
o Note: Never use a regular "household" vacuum cleaner, especially when
cleaning toxic material such as lead, or asbestos. Use a vacuum
specifically designed for industrial workplaces and be sure to use
appropriate filters, etc.
 Use steam cleaning instead of solvent degreasing (but be sure to evaluate the
potential high temperature hazard being introduced such as heat stress).
 Use electric motors rather than diesel ones to eliminate diesel exhaust
emissions.
 Float "balls" on open-surface tanks that contain solvents (e.g. degreasing
operations) to reduce solvent surface area and to lower solvent loss.
 Instead of conventional spray painting, try to dip, paint with a brush, or use
"airless" spray paint methods. These methods will reduce the amount of paint
that is released into the air.
 Decrease the temperature of a process so that less vapour is released.
 Use automation - the less workers have to handle or use the materials, the less
potential there is for exposure.
 Use mechanical transportation rather than manual methods.

Enclosure and Isolation

These methods aim to keep the chemical "in" and the worker "out" (or vice versa).
An enclosure keeps a selected hazard "physically" away from the worker. Enclosed
equipment, for example, is tightly sealed and it is typically only opened for cleaning
or maintenance. Other examples include "glove boxes" (where a chemical is in a
ventilated and enclosed space and the employee works with the material by using
gloves that are built in), abrasive blasting cabinets, or remote control devices. Care
must be taken when the enclosure is opened for maintenance as exposure could occur
if adequate precautions are not taken. The enclosure itself must be well maintained to
prevent leaks.
Isolation places the hazardous process "geographically" away from the majority of the
workers. Common isolation techniques are to create a contaminant-free or noise-free
booth either around the equipment or around the employee workstations.

Ventilation

Ventilation is a method of control that strategically "adds" and "removes" air in the
work environment. Ventilation can remove or dilute an air contaminant if designed
properly. Local exhaust ventilation is very adaptable to almost all chemicals and
operations. It removes the contaminant at the source so it cannot disperse into the
work space and it generally uses lower exhaust rates than general ventilation (general
ventilation usually exchanges air in the entire room).
Local exhaust ventilation is an effective means of controlling hazardous exposures but
should be used when other methods (such as elimination or substitution) are not
possible.
A local exhaust ventilation system consists of these basic parts:

1. A hood that captures the contaminants generated in the air (at the source).
2. Ductwork (exhaust stack and/or recirculation duct) that carries the
contaminated air to the air cleaning device, if present or to the fan (away from
the source).
3. A fan which draws the air from the hood into the ducts and removes the air
from the workspace. The fan must overcome all the losses due to friction, hood
entry, and fittings in the system while producing the intended flow rate.
4. Air cleaning devices may also be present that can remove contaminants such as
dust (particulates), gases and vapours from the air stream before it is
discharged or exhausted into the environment (outside air), depending on the
material(s) being used in the hood.

Figure 4

The design of a ventilation system is very important and must match the particular
process and chemical or contaminant in use. Expert guidance should be sought. It is a
very effective control measure but only if it is designed, tested, and maintained
properly.
Because contaminants are exhausted to the outdoors, you should also check with your
local environment ministry or municipality for any environmental air regulations or
bylaws that may apply in your area.

What are examples of systems that increase awareness?

Systems that increase awareness are methods that help the worker to detect if a hazard
is present. Examples of these hazard controls include warning systems, visual or
audible alarms, warning signs, or other indicators that alert the worker to a situation.

Administrative

Example: The Riverside Inc. warehouse suffers a series of workplace injuries related
to improper operation of forklifts. Company managers begin a thorough retaining and
certification program for all operators.

Administrative controls seek to improve workplace safety by creating safer procedures

in the workplace. Controls can range from the placement of warning signs throughout
a facility, employee training programs, and the use of safety tape.

Once companies reach the administrative level, they start to place the onus of
workplace safety on staff instead of management, and the results are unpredictable.
Warning signs are only effective if employees heed the warning, but many employees
choose to ignore safety procedures in order to save time or effort.

What are examples of administrative controls?

Administrative controls limit workers' exposures by scheduling shorter work times in
contaminant areas or by implementing other "rules". These control measures have
many limitations because the hazard itself is not actually removed or reduced.
Administrative controls are not generally favoured because they can be difficult to
implement, maintain and are not a reliable way to reduce exposure. When necessary,
methods of administrative control include:

 Restricting access to a work area.

 Restricting the task to only those competent or qualified to perform the work.
 Scheduling maintenance and other high exposure operations for times when
few workers are present (such as evenings, weekends).
 Using job-rotation schedules that limit the amount of time an individual worker
is exposed to a substance.
 Using a work-rest schedule that limits the length of time a worker is exposure
to a hazard.

Work Practices

Work practices are also a form of administrative controls. In most workplaces, even if
there are well designed and well maintained engineering controls present, safe work
practices are very important. Some elements of safe work practices include:
  Developing and implementing safe work procedures or standard operating
procedures.
 Training and education of employees about the operating procedures as well as
other necessary workplace training (including WHMIS).
 Establishing and maintaining good housekeeping programs.
 Keeping equipment well maintained.
 Preparing and training for emergency response for incidents such as spills, fire
or employee injury.

Education and Training

Employee education and training on how to conduct their work safely helps to
minimize the risk of exposure and is a critical element of any complete workplace
health and safety program. Training must cover not only how to do the job safely but
it must also ensure that workers understand the hazards and risks of their job. It must
also provide them with information on how to protect themselves and co-workers.

Good Housekeeping

Good housekeeping is essential to prevent the accumulation of hazardous or toxic

materials (e.g., build-up of dust or contaminant on ledges, or beams), or hazardous
conditions (e.g., poor stockpiling).
For more information about workplace housekeeping, please see the OSH Answers
document Workplace Housekeeping - Basic Guide.
For more information about combustible dust, please see the OSH Answers
document Combustible Dusts.

Figure 5
Emergency Preparedness

Being prepare for emergencies means making sure that the necessary equipment and
supplies are readily available and that employees know what to do when something
unplanned happens such as a release, spill, fire or injury. These procedures should be
written and employees should have the opportunity to practice their emergency
response skills regularly.

Personal Hygiene Practices and Facilities

Personal hygiene practices are another effective way to reduce the amount of a
hazardous material absorbed, ingested or inhaled by a worker. They are particularly
effective if the contaminant(s) can accumulate on the skin, clothing or hair.
Examples of personal hygiene practices include:

 Washing hands after handling material and before eating, drinking or smoking.
 Avoiding touching lips, nose and eyes with contaminated hands.
 No smoking, drinking, chewing gum or eating in the work areas - these
activities should be permitted only in a "clean" area.
 Not storing hazardous materials in the same refrigerator as food items.

Personal Protective Equipment (PPE)

Example: Mike’s Machining uses a press loud enough to damage employee hearing.
Mike offers the crew ear protection.
The least effective of all the safety controls is reliance on PPE. PPE is any piece of
additional equipment, like helmets, gloves, or safety goggles that protect employees
from workplace hazards.

Though PPE seems like the most obvious choice to improve safety, the high failure
rate makes PPE useless for all but the most minor of hazards. A helmet is not going to
protect an employee from a falling steel beam, and goggles can only withstand so
much force before they break under pressure. PPE is a fine step when taken as part of
a larger safety effort, but should never be the primary focus of safety controls.

NIOSH’s PtD program argues that safety should be a primary concern of employers
from the conception of the business through to the operation. An approach that
focuses heavily on prevention from the very beginning will foster a culture of safety
within management and staff that enables safety protocols to take root.

The five-tier hierarchy of safety controls from NIOSH reveals several key areas where
companies can improve the safety conditions of their workplace, and protect
employees in the process. Companies must use all five tiers to develop a complete
safety plan, but over reliance on any one step can have devastating consequences.

What should I know about personal protective equipment (PPE) as a hazard

control method?
Personal protective equipment (PPE) includes items such as respirators, protective
clothing such as gloves, face shields, eye protection, and footwear that serve to
provide a barrier between the wearer and the chemical or material.
It is the final item on the list for a very good reason. Personal protective equipment
should never be the only method used to reduce exposure except under very specific
circumstances because PPE may "fail" (stop protecting the worker) with little or no
warning. For example: "breakthrough" can occur with gloves, clothing, and respirator
cartridges.
No matter which type of PPE is used, it is essential to have a complete PPE program
in place. For more information about PPE programs, please see the following
document Designing an Effective PPE Program.