1. Introduction
Once a hazard has been successfully identified and those associated risk assessed, the next vital step is the development and implementation of effective control measures. This process is not just about ticking off safety requirements or completing safety checklists, it's about making real impact, practical decisions that keep people safe, prevent environmental adverse impact, and ensure the business continuity and improvement.
They are the result of careful planning, technical evaluation, worker input, and a deep understanding of how the work is actually done. In this article, we outline how organisations can develop control measures that are technically strong, workable, sustainable, and understood by everyone involved.
2. The Purpose of Control Measures
The primary goal of control measures is to either eliminate a hazard or reduce the risk it poses to an acceptable level (As Low As Reasonably Practicable – ALARP). This means applying control measures that are proportional to the level of associated risk and the severity of potential consequences.
Control measures serve to:
- Prevent incidents and injuries
- Ensure compliance with legal and regulatory obligations
- Protect against adverse environmental impact
- Promote a positive health and safety culture of accountability and awareness
3. Guiding Principles for Control Development
When developing and designing safety control measures, Companies are guided by several key principles:
- Prioritise elimination and engineering controls over PPE and administrative fixes
- Involve frontline workers in the development process to get detailed insight
- Consider how people interact with processes and equipment in real life
- Ensure controls are practical, enforceable, and regularly reviewed and monitored
- Tailor controls to specific environments, tasks, and risk levels
Note: Control measures must not create new hazards or transfer risk to other parts of the operation without mitigation.
4. The Hierarchy of Controls
Many orgnaisation adopted the internationally recognised Hierarchy of Controls to structure the development of safety control measures. This hierarchy helps us choose the most effective control strategies by considering five levels from most effective to least:
4.1 Elimination (Most Effective)
Removing the hazard entirely is always the best option, but in some cases it's quite difficult. If the hazard doesn't exist, it can't cause harm.
Examples:
- Designing out confined spaces during planning stages
- Eliminating manual lifting by automating material handling
- Stopping use of a hazardous substance
4.2 Substitution
This involves replacing a hazardous element with something less harmful and less hazardous.
Examples:
- Using non-toxic chemicals in place of toxic ones
- Replacing a diesel-powered tool with an electric one to avoid fumes or using a battery-operated more safer
- Swapping a high-noise tool for a quieter model
4.3 Engineering Controls
These are physical changes to processes, equipment, or the work environment that isolate people from hazards.
Examples:
- Installing guards on machinery
- Using ventilation systems to extract fumes
- Building barriers or guardrails at height
4.4 Administrative Controls
These involve changes to the way work is organised and carried out.
Examples:
- Creating safe work procedures (SWPs)
- Training and supervision
- Signage and warning systems
- Rotation of workers to reduce exposure times or changes in time
4.5 Personal Protective Equipment (PPE) (Least Effective)
PPE is the last line of defence. It does not eliminate the hazard but protects the worker from exposure.
Examples:
- Hard hats, gloves, goggles
- Respirators or hearing protection
- Fall arrest harnesses
5. Process for Developing Control Measures
5.1 Understand the Task in Detail
Before choosing any control, it's essential to fully understand how a task is performed. This includes:
- Step-by-step task breakdown (e.g. through Job Hazard Analysis or Safe Work Method Statements)
- Identifying who is involved and when (Who might be harmed and how)
- Recognising variables (e.g. weather, location, equipment condition)
5.2 Evaluate Feasibility and Effectiveness
Not every control is feasible in every situation. The process itself shall include evaluating:
- Technical feasibility: Can it be implemented with available resources and knowledge?
- Operational feasibility: Will it interfere with productivity or introduce new inefficiencies?
- Economic feasibility: Are the costs reasonable in proportion to the risk?
5.3 Implement Control Measures
Once developed and approved from the relevant department or HSE department, control measures are implemented in alignment with project schedules or operational timelines. This may involve:
- Engineering changes need to adopt and implement
- Procurement of new equipment or materials as per local and international standards
- Staff training and competency verification and evaluation
- Updates to work procedures and documentation as per the recent changes
- Installation of signage, barriers, or monitoring systems
5.4 Communicate and Train
A control measure is only effective if the people are regularly trained for that and understand it.
That’s why companies have to invest time and money in:
- Toolbox talks to explain new controls and why they’re important
- Hands-on demonstrations for using equipment or PPE
- Written procedures that are clear, accessible, and translated where necessary
- Competency checks to confirm understanding
5.5 Monitor and Maintain
Controls must be regularly monitored for both compliance and ongoing effectiveness.
We have to use the relevant checklist & forms:
- Routine inspections
- Incident and near-miss reports
- Worker feedback
- HSE audits and internal reviews
