Winter Safety Zone: Hierarchy of Controls | Hard Hats or Helmets

Winter 2025 The Hierarchy of Controls: A Roadmap to Reduce Risk The Hierarchy of Controls is one of the first concepts introduced to a safety professional. It is a general roadmap to reduce risk or potential injury of an exposed employee or individual to a hazard. Once a hazard is identified, we often forget to use this basic tool to identify how to reduce risk. The Hierarchy of Controls identifies a preferred order of actions to best control hazardous workplace exposures. The goal is to identify the control method which is most doable but also achieves the maximum level of risk reduction. This inverted pyramid representation presents the method with the most risk reduction at the top of the inverted pyramid and presents the order of evaluation to minimize the risk, starting at the top. Often, the risk minimization process involves two or more of the control methods together. The first control method to be considered is Elimination, which removes the hazard at the source. This could include changing the work process to stop using a toxic chemical, heavy object, or sharp tool. It is the preferred solution to protect workers because no exposure can occur. The second method, Substitution, replaces the hazard using a safer alternative to the source of the hazard. An example of Substitution is using a safer chemical in a process than the one currently used. This option does not remove 100% of the risk, but can reduce the hazard considerably or to a level that can be better managed by additional methods such as PPE. The third method uses Engineering Controls. This is best demonstrated when guards or safety shields are put in place to keep workers safe from danger. Another example is an improved ventilation system designed and installed to remove airborne hazards. Engineering is often used to reduce noise hazards created by a machine process or to insulate the noise from the operator. This can reduce the hazard but, as illustrated by the Hierarchy of Controls, is in the mid-range of effectiveness. Administrative Controls, the fourth method, can be used to reduce exposure to workplace hazards by modifying work procedures. For example, workers might be restricted to a certain amount of time in noisy areas, lowering their average noise exposure level. Or a new policy could require certain procedures to reduce the potential for injury. Posting signage can warn of hazardous conditions or remind workers to use caution or PPE. The lower effectiveness of this control method is due to human nature — assuming workers will always follow the procedure or instructions. The final and least effective level of risk control is Personal Protective Equipment (PPE). Masks, breathing apparatus, ear plugs, gowns or other outer protective clothing, gloves, safety glasses, goggles, shields are examples of PPE. The worker must select proper PPE, be properly trained, and comply to gain the desired level of protection. While this method is the most familiar approach to risk control, it's actually the least effective in reducing risk. Again, it requires compliance as well as proper training and consistent use by the worker to be most effective. Two or more of these methods can be combined to achieve maximum risk reduction. To reduce dust exposure, a company might install a ventilation system, require workers to wear masks, and limit the amount of time workers spend in dusty areas. In this example three methods are used — engineering control, administrative control, and PPE — to achieve the safest working condition. The hierarchy of controls can be thought of in the way depicted below from best to least effective at reducing risk. Remove – Replace – Redesign – Manage – Train – Warn - Protect When identifying the best way to reduce risk or potential for injury, consider the Hierarchy of Controls to determine which method or methods would best achieve the risk reduction goal for maximum safety.   Using Hard Hats? Helmets May Be Safer The use of head protection for workers can be traced back to the salt mines, as well as tin and copper miners who wore hats of leather or felt hardened with resin to protect their heads. A trademark was granted to the E. D. Bullard Co. for the hard-boiled hat made of steam boiled canvas, a leather brim, glue, and black paint. These helmets were inspired by those worn into battle by soldiers during World War I. A helmet secured by a chin strap was the standard used by Roman soldiers in 400 B.C. Manufacturers and construction companies began to use hard hats more in the early 1900s, including projects like the construction of the Golden Gate Bridge and the Hoover Dam. Modern hard hats are constructed using thermoplastics, fiberglass, and polycarbonate resin. Current ANSI Standards have specified criteria for hard hat design and performance. Today's OSHA Standards require hard hats as head protection in many industrial and construction applications. But it appears a change in head protection is on the horizon. In late 2023, OSHA announced a switch from the traditional hard hat to the safety helmet for the agency's employees. While a hard hat may fall off the head during a slip or fall, the helmet stays in place because of the chinstrap and provides improved protection from side impacts. The helmet also shows improved performance for impact resistance and can be more easily fitted with additional safety accessories such as face shields, welding shields, head lamps, and earmuffs for hearing protection and/or communication. The enforcement of head protection by occupational standards has improved the incidence and seriousness of head trauma from falls and injuries, but many still occur every year. The injury is often Traumatic Brain Injury (TBI), which interferes with normal brain function and can have lifelong effects. Most of these injuries occur as a result of automobile accidents, recreational sports, and construction and extraction industries. When examining injury data from these industries it is clear that workers could benefit from the switch from hard hats to helmets to improve protection from head trauma and TBI injuries. There is currently no standard in the U.S. to require the switch to helmets, however, some countries have updated their standards to require helmet use. Some specific working conditions in the U.S. can require helmets and many construction companies have included helmet use as part of their PPE requirements. Helmets have greatly reduced the incidence of TBIs due to the use of better shock-absorbing material, added protection from side and rear impacts, the presence of a chin strap, and impacts that would dislodge a hard hat. UPCOMING EVENTS/LABOR NEWS APRIL 18: ONE DAY MINE RESCUE SKILLS COMPETITION Farmington, MO The National Safety Council has a safety calendar of events – Check it out. Contributing authors: David K. Attebery, M.S., CSP Mine and Cave Safety Program Manager Cited source material: PSJ – Professional Safety Journal of the American Society of Safety Professionals, August and September issue, 2024. Click here to view this email in a web browser.   Questions? Contact Us STAY CONNECTED: SUBSCRIBER SERVICES: Manage Subscriptions  |  Help This email was sent to ignoble.experiment@arconati.us using GovDelivery Communications Cloud on behalf of: Missouri Department of Labor · P.O. Box 59 · Jefferson City, MO 65104-0059 · 1-800-320-2519