Chapter 5: Hazard Identification, Assessment and Control¶
5.0 Purpose and Scope¶
This chapter establishes 4Core's systematic approach to identify, assess, and control workplace hazards. This framework ties together all safety programs and ensures hazards are recognized and managed before they cause harm.
Core Principle: Hazards must be identified and controlled BEFORE work begins. If new hazards emerge during work, stop and reassess.
Continuous Process: Hazard identification ongoing, not one-time event; all workers responsible for identifying/reporting hazards; risk assessments reviewed when conditions change; controls verified for effectiveness.
Integration: This chapter provides overall framework; specific programs (Chapters 3-4) provide detailed controls for known hazards; Job Hazard Analysis applies framework to specific tasks.
5.1 Hazard Identification¶
5.1.1 Hazard Definition¶
Hazard: Anything with potential to cause injury, illness, property damage, or environmental harm.
Hazard Categories in our work: - Physical: Confined spaces, heights, moving equipment, extreme temperatures, noise, radiation - Chemical: Thermal oil, combustion products, welding fumes, solvents, asbestos - Biological: Mold, bacteria, rodent droppings, hantavirus - Ergonomic: Repetitive motions, awkward postures, heavy lifting, vibration - Psychosocial: Workplace stress, fatigue, working alone, harassment
Hazard vs. Risk: Hazard = thing that can cause harm (thermal oil at 300°C); Risk = likelihood and severity of harm occurring (high risk if controls inadequate, low risk if properly controlled).
5.1.2 Hazard Identification Methods¶
| Method | Description |
|---|---|
| Workplace Inspections | Regular scheduled inspections of sites, equipment, practices; formal process with checklists/documentation; identifies existing hazards and deteriorating conditions (Chapter 8) |
| Job Hazard Analysis (JHA) | Systematic breakdown of job tasks; conducted before new/non-routine work; involves workers who perform task; documents hazards/controls for each step (Section 5.4) |
| Incident Investigation | Analysis of incidents, near misses, injuries; identifies root causes/contributing factors; reveals hazards missed or inadequately controlled; drives corrective actions (Chapter 9) |
| Pre-Job Planning | Review of upcoming work; client site assessments before work; coordination with client for site-specific hazards (Section 4.6) |
| Worker Reports | Workers report observed hazards; near-miss reporting captures "close calls"; suggestion programs; no discipline for good faith reporting |
| Safety Meetings | Toolbox talks discuss seasonal/task-specific hazards; monthly meetings review hazards/trends; management reviews analyze incident data (Chapter 7) |
| Management of Change (MOC) | Identifies hazards from changes to equipment, procedures, materials, work locations, personnel, organization (Section 5.6) |
| External Sources | WorkSafe BC alerts/bulletins; industry safety publications; equipment manufacturer warnings; client hazard assessments; other contractors' experiences |
Daily Hazard Identification: Workers scan work area before beginning; pre-use equipment inspections; atmospheric testing in confined spaces; monitoring changing conditions throughout day.
Workers must report immediately: Unsafe condition/practice; equipment defects/malfunctions; changes in work conditions (weather, site, scope); near misses; new/unexpected hazards.
Reporting Methods: Verbal to supervisor (immediate hazards); written hazard report form (documented for tracking); during toolbox talks/safety meetings; anonymous reporting available.
5.2 Risk Assessment¶
5.2.1 Risk Assessment Framework¶
Risk = Likelihood × Severity
Purpose: Prioritize hazards for control (address highest risks first); determine appropriate level of controls; justify resources for hazard control; demonstrate due diligence.
5.2.2 Risk Assessment Matrix¶
4Core uses 3×3 risk matrix for simplicity and practicality:
Likelihood Levels:¶
| Level | Description | Examples |
|---|---|---|
| Low (1) | Unlikely during normal operations | Boiler explosion with proper maintenance, catastrophic equipment failure |
| Medium (2) | Could happen occasionally | Minor burns from hot surfaces, slips on wet floors, minor cuts |
| High (3) | Likely without controls | Oxygen deficiency in confined space, thermal oil exposure during maintenance |
Severity Levels:¶
| Level | Description | Injury/Damage Examples |
|---|---|---|
| Low (1) | Minor injury, no lost time, minimal damage | First aid only, bruises, minor cuts, superficial burns |
| Medium (2) | Medical treatment required, possible lost time | Stitches, minor fractures, moderate burns, equipment repair needed |
| High (3) | Serious injury, permanent disability, fatality, major damage | Hospitalization, major burns, confined space fatality, serious chemical exposure |
Risk Level Matrix:¶
| LIKELIHOOD | Severity: Low (1) | Severity: Medium (2) | Severity: High (3) |
|---|---|---|---|
| High (3) | Medium (3) | High (6) | High (9) |
| Medium (2) | Low (2) | Medium (4) | High (6) |
| Low (1) | Low (1) | Low (2) | Medium (3) |
Risk Level Actions:¶
| Risk Level | Score | Required Action | Timeline |
|---|---|---|---|
| High | 6-9 | STOP WORK. Implement immediate controls. Cannot proceed until risk reduced to Medium or Low. Management approval required. | Immediate |
| Medium | 3-4 | Controls required before work proceeds. Document controls in JHA or work plan. Supervisor approval required. | Before work begins |
| Low | 1-2 | Standard controls sufficient. Verify controls in place. Proceed with caution and monitoring. | Routine verification |
5.2.3 Conducting Risk Assessment¶
- Identify Hazard: What is it? Where/when does it occur? Who is exposed?
- Assess Likelihood: How often could exposure occur? Consider frequency, number of people, duration. Assume NO controls in place (assess inherent risk first).
- Assess Severity: What is worst realistic outcome? Consider most vulnerable workers. Based on what HAS happened in industry, not speculation.
- Determine Risk Level: Use matrix to calculate risk score; document risk level (High, Medium, Low).
- Select Controls: Apply hierarchy of controls (Section 5.3); implement controls to reduce risk; reassess risk with controls in place (residual risk); verify residual risk acceptable (Medium or Low).
- Document and Communicate: Document in JHA, work plan, or hazard assessment form; communicate to affected workers; review with supervisor for approval; update as conditions change.
Reassess risk when: Work scope/methods change; new hazards identified; incidents/near misses occur; controls prove ineffective; regulatory requirements change; annually as part of program review.
5.3 Hierarchy of Controls¶
5.3.1 Control Hierarchy (Most to Least Effective)¶
- Elimination - Remove hazard entirely (MOST EFFECTIVE)
- Substitution - Replace with less hazardous alternative
- Engineering Controls - Physical changes to isolate workers from hazards
- Administrative Controls - Work procedures and policies
- Personal Protective Equipment (PPE) - Last line of defense (LEAST EFFECTIVE)
Key Principle: Always apply highest level of control feasible. PPE alone never sufficient when higher controls possible. Often several levels used together for adequate protection (layered defense).
5.3.2 Control Levels with Examples¶
| Control Level | Definition | Examples in Our Work | Benefits | Limitations |
|---|---|---|---|---|
| Elimination | Completely remove hazard | Cancel confined space work (work from outside); eliminate hot work (use mechanical fasteners instead of welding); remove asbestos before maintenance; redesign system to eliminate heights | 100% effective; no ongoing maintenance; no reliance on worker behavior | Often not feasible (work must be done); may be cost-prohibitive |
| Substitution | Replace with less hazardous alternative | Water-based cleaners vs. solvents; scaffolding vs. ladders; electric tools vs. pneumatic (noise); lower temperature setpoints | Reduces hazard at source; relatively permanent solution | Ensure substitute actually less hazardous; may affect work quality/efficiency |
| Engineering | Physical modifications isolating workers | Forced-air ventilation (confined space); machine guards; guardrails; lockout devices; fall arrest anchor points; fixed gas detection; emergency showers/eyewash; fire suppression | Automatic protection; protects multiple workers; often permanent | Capital investment required; may not be feasible on client sites; requires maintenance |
| Administrative | Procedures, policies, training | Confined space entry procedures; hot work permits; lockout procedures; JHAs; work scheduling/rotation; training/competency; warning signs/labels; permits/approvals | Low cost; flexible; can implement quickly | Relies on worker compliance; requires supervision/enforcement; ongoing training/communication needed |
| PPE | Equipment worn to protect worker | Hard hats, safety glasses, footwear; gloves (cut, heat, chemical); respiratory protection; fall protection harness; FR clothing; hearing protection | Last line of defense; appropriate for short-duration exposures; backup protection | Protects only wearer; fails if damaged/worn incorrectly/not used; can create additional hazards (heat stress, reduced visibility/communication) |
Applying Hierarchy - Example: Grinding in Confined Space - Elimination: Redesign to eliminate grinding (not feasible - work must be done) - Substitution: Mechanical cleaning instead of grinding (may be feasible for some tasks) - Engineering: Forced-air ventilation to remove dust; guard on grinder to control sparks; anchor points for fall protection - Administrative: Hot work permit; confined space entry permit; atmospheric monitoring during work; limited duration exposures (rotate workers); training on proper grinding techniques - PPE: Respiratory protection (P100 filter); face shield and safety glasses; hearing protection; gloves (vibration, cuts); fall protection harness
Result: Multiple layers of control applied - no single control sufficient alone. (See Section 3.13 for PPE Program)
5.4 Job Hazard Analysis (JHA)¶
5.4.1 JHA Definition and Requirements¶
Job Hazard Analysis (JHA): Systematic process to identify hazards associated with each step of job and determine controls. Other names: Job Safety Analysis (JSA), Safe Work Procedure, Task Hazard Analysis.
JHA Required: Before new/non-routine work; when work methods/equipment change; after incidents/near misses on similar tasks; for high-hazard work (confined space, hot work, heights); when multiple trades in same area; annually for routine tasks (review/update).
Who Conducts: Supervisor or competent person leads; workers who perform task participate (they know job best); Safety Officer provides technical support; client representatives included if on client site.
5.4.2 JHA Process¶
- Select Job: Choose job to analyze; define scope clearly; ensure job broken into manageable task.
- Break into Steps: List each major step in sequence; use 5-12 steps (too few = missing hazards, too many = overwhelming); focus on what worker does, not how; use action verbs (move, cut, lift, enter, test).
- Identify Hazards for Each Step: What can go wrong? What hazards exist (physical, chemical, ergonomic, etc.)? What are consequences?
- Assess Risk: Use risk matrix (Section 5.2.2); determine likelihood and severity; calculate risk level (High, Medium, Low).
- Determine Controls: Apply hierarchy of controls (Section 5.3); specify what controls will be used; assign responsibility for implementing controls; verify controls in place before proceeding.
- Document JHA: Use JHA form or template; include all steps, hazards, risk levels, controls; obtain supervisor approval; communicate to workers before job begins.
- Review and Update: Review before each use; update if conditions change during work; revise after incidents or when better controls identified; annual review for routine tasks.
Example JHA Steps: Confined Space Entry for Boiler Tube Inspection 1. Obtain entry permit and review entry plan 2. Isolate boiler (lockout, drain, cool) 3. Set up ventilation and atmospheric monitoring 4. Test atmosphere and verify acceptable conditions 5. Don required PPE and enter boiler 6. Conduct tube inspection 7. Exit boiler and secure entry point 8. Restore boiler to service
Example Hazards (Step 5): Oxygen deficiency, confined space atmosphere, restricted entry/exit, heat stress, slip/trip hazards on internal surfaces.
Example Controls (Step 5): Continuous atmospheric monitoring (LEL, O₂, CO, H₂S); attendant maintains continuous communication with entrant; supplied-air respirator (if atmosphere not acceptable); fall protection if vertical entry; adequate lighting inside boiler; non-slip footwear; cool boiler to safe temperature before entry.
5.4.3 JHA Documentation and Field Use¶
Minimum JHA documentation: Job/task description; date prepared and participants; step-by-step breakdown; hazards for each step; risk assessment (likelihood, severity, risk level); controls selected (hierarchy applied); PPE required; emergency procedures; approval signatures.
JHA Records: Retain with job file; 2 years minimum retention; updated JHAs replace old versions (retain revision history).
Before work: Review JHA with entire crew during toolbox talk; verify controls in place/functional; ensure workers understand roles/responsibilities; confirm emergency procedures understood.
During work: Keep JHA accessible at work site for reference; stop if conditions change from what was assessed; update JHA if new hazards identified; report deviations/problems to supervisor.
After work: Debrief crew on what went well and what could improve; note changes needed to JHA; report near misses/incidents; update JHA for next use if necessary.
5.5 Pre-Job Planning and Hazard Assessment¶
5.5.1 Pre-Job Planning Levels¶
All work requires pre-job planning to: Identify hazards before work begins; determine appropriate controls; allocate resources (crew, equipment, time); coordinate with clients/other trades; establish communication/emergency procedures.
| Level | Hazard Category | Requirements | Examples |
|---|---|---|---|
| Level 1 - Routine | Low Hazard | Brief supervisor review; verbal communication in toolbox talk; standard controls verified | Shop work, routine maintenance with no CS/hot work/heights |
| Level 2 - Non-Routine | Moderate Hazard | Written hazard assessment or simple JHA; supervisor approval; client coordination; permits may be required | Client site work, maintenance involving lockout, mobile equipment use |
| Level 3 - High-Hazard | High Hazard or Complex | Formal JHA required; management approval; multiple permits (CS, hot work, fall protection); client coordination/approvals; emergency response planning | Confined space entry, hot work in CS, work at heights, thermal oil system maintenance |
5.5.2 Pre-Job Hazard Assessment Process¶
- Gather Information: Scope/drawings/specs; client site information/requirements; previous JHAs for similar work; equipment/materials to be used; environmental conditions (weather, temperature).
- Conduct Site Walkthrough: Visual inspection of work area; identify confined spaces, fall hazards, energy sources; locate emergency equipment/exits; assess housekeeping/access; identify other trades/activities in area.
- Identify Hazards: Use checklist or hazard categories (physical, chemical, biological, ergonomic, psychosocial); consider all phases (setup, work, cleanup); involve workers; review client hazard assessments.
- Assess and Control Risks: Apply risk assessment process (Section 5.2); select controls using hierarchy (Section 5.3); develop JHA for high-hazard work (Section 5.4); obtain permits as required.
- Plan Resources: Crew size/qualifications verified; equipment/tools/PPE identified and available; materials/supplies obtained; time allocated realistically.
- Establish Communication: Emergency contacts identified; communication methods established (phone, radio); client coordination confirmed; toolbox talk scheduled.
- Obtain Approvals: Supervisor reviews/approves plan; management approval for high-hazard work; client permits/authorizations obtained.
Site-Specific Assessment: Environmental hazards (weather, terrain, overhead/underground hazards, wildlife); site-specific hazards (other workers/contractors, operating equipment nearby, traffic, client emergency procedures/assembly points, site access/egress, restricted areas); documentation (photograph site conditions, document client discussions, record hazards in JHA, update as conditions change).
5.6 Management of Change (MOC)¶
5.6.1 Purpose and Triggers¶
Management of Change (MOC): Systematic process to identify/control new hazards introduced by changes to equipment, processes, materials, personnel, or procedures.
Why MOC Important: Changes often introduce unexpected hazards; "temporary" changes become permanent without review; workers may not recognize new risks; incidents often occur shortly after changes.
When MOC Required: Before implementing changes to work activities, equipment, or materials; changes may be temporary or permanent; "try it and see" without assessment NOT acceptable.
5.6.2 Changes Requiring MOC¶
| Change Category | Examples |
|---|---|
| Equipment and Tools | New equipment purchased/rented; modifications to existing equipment; substitution of different tools; changes to equipment maintenance procedures |
| Work Procedures | New work methods/techniques; changes to safe work procedures; elimination of procedure steps; changes to permit/approval requirements |
| Materials and Chemicals | New chemicals/materials introduced; change in supplier/product formulation; substitution of materials; changes in quantities used/stored |
| Work Locations | New client sites/work areas; changes to shop layout; relocation of equipment/materials; work in areas not previously assessed |
| Personnel | New positions/roles created; changes to crew sizes/composition; reassignment of responsibilities; contractors/subcontractors for new tasks |
| Organizational | Changes to reporting structure; new policies/procedures; changes to training requirements; regulatory requirement changes |
5.6.3 MOC Process¶
- Propose Change: Describe clearly (what, why, when, who affected); identify reason (improvement, cost, efficiency, compliance); determine if MOC review required (if in doubt, conduct review).
- Assess Hazards: What new hazards introduced? What existing hazards affected (increased, decreased, eliminated)? Who is affected? Are current controls still adequate?
- Conduct Risk Assessment: Apply risk assessment process (Section 5.2); consider worst-case scenarios; involve affected workers.
- Determine Controls: Apply hierarchy of controls (Section 5.3); update affected procedures, JHAs, or programs; identify new equipment, training, or PPE needed; establish verification/monitoring methods.
- Obtain Approvals: Supervisor reviews/approves minor changes; management approves significant changes; Safety Officer reviews changes affecting safety programs; client approval for changes affecting client systems.
- Implement Change: Communicate to all affected workers; provide training on new procedures/equipment; update documentation (procedures, JHAs, training materials); monitor initial implementation closely.
- Verify Effectiveness: Confirm controls working as intended; gather worker feedback; adjust if problems identified; document lessons learned.
MOC Documentation: Description of proposed change; hazard assessment/risk evaluation; controls implemented; training provided; approval signatures/dates; verification of effectiveness. Retention: 2 years minimum, permanent recommended for significant changes.
Emergency Changes: When immediate change necessary: implement temporary controls immediately; document change/rationale; conduct formal MOC review within 72 hours; replace temporary with permanent controls; communicate change/rationale to affected workers.
5.7 Verification of Controls¶
Controls verified to ensure: In place and functional before work begins; remain effective throughout work; actually used by workers (administrative controls, PPE); maintained properly (engineering controls).
Verification Methods: - Pre-Work: Supervisor inspects work area before crew begins; equipment pre-use inspections completed; atmospheric testing confirms acceptable conditions (CS); lockout verified with zero-energy test; fall protection anchor points inspected/rated; PPE fit/function checked. - During Work Monitoring: Supervisor visits work site to observe practices; continuous atmospheric monitoring (when required); communication maintained with workers in hazardous areas; workers self-monitor and report changes. - Inspections: Regular workplace inspections identify control deficiencies; equipment inspections verify guards/safety devices functional (Chapter 8). - Worker Feedback: Workers report when controls not working as intended; suggestions for improved controls encouraged; near-miss reports reveal control failures before injury.
If controls ineffective: Stop work immediately if risk high; implement temporary controls if possible; investigate why control failed (design flaw, maintenance issue, not used correctly); implement corrective actions; update procedures/JHAs; retrain workers if necessary; do not resume work until effective controls in place.
5.8 Hazard Communication¶
Workers informed of hazards through: - Training: General safety orientation covers common hazards; task-specific training for high-hazard work; toolbox talks address current/seasonal hazards (Chapter 6). - Written Information: Job Hazard Analyses reviewed before work; Safety Data Sheets (SDS) for chemicals; equipment manuals/safe operating procedures; posted signs/warnings. - Verbal Communication: Pre-job briefings discuss daily hazards; supervisor communicates changes/new hazards; workers communicate hazards to each other. - Visual Warnings: Signs/labels on equipment and chemicals; barricades and flagging around hazard areas; colored tags (lockout tags, "Do Not Use" tags).
WHMIS Hazard Communication: Supplier labels on containers; workplace labels on secondary containers; SDS accessible to workers; WHMIS training for all workers handling chemicals (Section 3.5).
Client Hazard Communication: Obtain client hazard assessments before work; participate in client safety orientation; understand client warning systems (alarms, lights, signs); communicate 4Core-created hazards to client; coordinate when multiple contractors present.
5.9 Roles and Responsibilities¶
| Role | Responsibilities |
|---|---|
| Management | Provide resources for hazard identification/control (training, equipment, time); ensure hazard assessment processes established/followed; review/approve high-hazard work plans/JHAs; support workers refusing unsafe work; ensure corrective actions implemented following incidents; conduct annual program review/update |
| Supervisors | Conduct pre-job planning/hazard assessments for work under supervision; lead JHA development with worker participation; verify controls in place before authorizing work; monitor work to ensure controls remain effective; stop work if new hazards emerge or controls fail; investigate incidents/implement corrective actions; communicate hazards to workers during toolbox talks |
| Safety Officer | Provide technical support for hazard assessments/JHAs; review high-hazard work plans/JHAs; conduct workplace inspections to identify hazards; analyze incident trends to identify emerging hazards; coordinate Management of Change reviews; maintain hazard assessment documentation/records; update safety programs based on identified hazards |
| Workers | Participate in hazard identification/JHA development; report hazards immediately to supervisor; follow established procedures/use required controls; use PPE as required; stop work if unsafe conditions develop; ask questions when unsure about hazards/controls; participate in inspections, meetings, training |
5.10 Documentation and Records¶
| Document Type | Retention |
|---|---|
| Job Hazard Analyses (JHAs) | 2 years minimum, longer if routine task performed regularly |
| Pre-job assessments | With job file, 2 years minimum |
| Management of Change (MOC) reviews | 2 years minimum, permanent for significant changes |
| Hazard reports | Until corrected, then 2 years |
| Risk assessments | 2 years minimum |
Continuous Improvement: Hazard assessment documentation used to identify trends in hazards/control failures; update safety programs/procedures; improve future JHAs/assessments; demonstrate due diligence to regulators; share lessons learned across organization.
END OF CHAPTER 5
Document Control
| Field | Value |
|---|---|
| Version | 0.9-DRAFT |
| Effective Date | December 2025 |
| Next Review | December 2026 |
| Approved By | [All 4 Owners] |
| Safety Officer | Rodney Peters |
Company Information: - Business Name: 4Core Energy & Maintenance Ltd. - Address: [To Be Added] - Industry: Energy and mechanical system maintenance, retrofits and troubleshooting - WorkSafe BC Account: [Account Number]