Engineering Controls

Hierarchy of Controls
Controlling exposures to occupational hazards is the fundamental method of protecting workers.

Traditionally, a hierarchy of controls has been used as a means of determining how to implement
feasible and effective controls. One representation of this hierarchy can be summarized as follows:
Elimination
Substitution
Engineering controls
Administrative controls
Personal protective equipment
The idea behind this hierarchy is that the control methods at the top of the list are potentially
more effective and protective than those at the bottom. Following the hierarchy normally leads to
the implementation of inherently safer systems, ones where the risk of illness or injury has been
substantially reduced.
Elimination and substitution, while most effective at reducing hazards, also tend to be the most
difficult to implement in an existing process. If the process is still at the design or development
stage, elimination and substitution of hazards may be inexpensive and simple to implement. For an
existing process, major changes in equipment and procedures may be required to eliminate or
substitute for a hazard.
Administrative controls and personal protective equipment are frequently used with existing
processes where hazards are not particularly well controlled. Administrative controls and personal
protective equipment programs may be relatively inexpensive to establish but, over the long term,
can be very costly to sustain. These methods for protecting workers have also proven to be less
effective than other measures, requiring significant effort by the affected workers.
Engineering controls are used to remove a hazard or place a barrier between the worker and the
hazard. Well-designed engineering controls can be highly effective in protecting workers and will
typically be independent of worker interactions to provide this high level of protection. The initial
cost of engineering controls can be higher than the cost of administrative controls or personal
protective equipment, but over the longer term, operating costs are frequently lower, and in some
instances, can provide a cost savings in other areas of the process
Engineering Controls
The first and best strategy is to control the hazard at its source. Engineering controls do
this, unlike other controls that generally focus on the employee exposed to the hazard.
The basic concept behind engineering controls is that, to the extent feasible, the work
environment and the job itself should be designed to eliminate hazards or reduce
exposure to hazards.
Engineering controls can be simple in some cases. They are based on the following
principles:
If feasible, design the facility, equipment, or process to remove the hazard or

substitute something that is not hazardous.
If removal is not feasible, enclose the hazard to prevent exposure in normal

operations.
Where complete enclosure is not feasible, establish barriers or local ventilation to

reduce exposure to the hazard in normal operations.
ngineering Controls
These controls focus on the source of the hazard, unlike other types of controls that generally
focus on the employee exposed to the hazard. The basic concept behind engineering controls is
that, to the extent feasible, the work environment and the job itself should be designed to
eliminate hazards or reduce exposure to hazards. While this approach is called engineering control,
it does not necessarily mean that an engineer is required to design the control.
Engineering controls are based on the following broad principles:
1. If feasible, design the facility, equipment, or process to remove the hazard and/or substitute
something that is not hazardous or is less hazardous.
Redesigning, changing, or substituting equipment to remove the source of excessive

temperatures, noise, or pressure;
Redesigning a process to use less toxic chemicals;
Redesigning a work station to relieve physical stress and remove ergonomic hazards; or
Designing general ventilation with sufficient fresh outdoor air to improve indoor air quality
and generally to provide a safe, healthful atmosphere.
2. If removal is not feasible, enclose the hazard to prevent exposure in normal operations.
Complete enclosure of moving parts of machinery;
Complete containment of toxic liquids or gases;
Glove box operations to enclose work with dangerous microorganisms, radioisotopes, or

toxic substances; and
Complete containment of noise, heat, or pressure-producing processes.
3. Where complete enclosure is not feasible, establish barriers or local ventilation to reduce
exposure to the hazard in normal operations. Examples include:
Ventilation hoods in laboratory work;
Machine guarding, including electronic barriers;
Isolation of a process in an area away from workers, except for maintenance work;
Baffles used as noise-absorbing barriers; and
Nuclear radiation or heat shields.
Administrative Controls
While safe work practices can be considered forms of administrative controls, OSHA uses
the term administrative controls to mean other measures aimed at reducing employee
exposure to hazards. These measures include additional relief workers, exercise breaks
and rotation of workers. These types of controls are normally used in conjunction with
other controls that more directly prevent or control exposure to the hazard.
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:
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 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.
Personal Protective Equipment (PPE)

When exposure to hazards cannot be engineered completely out of normal operations or
maintenance work, and when safe work practices and other forms of administrative
controls cannot provide sufficient additional protection, a supplementary method of
control is the use of protective clothing or equipment. This is collectively called personal
protective equipment, or PPE. PPE may also be appropriate for controlling hazards while
engineering and work practice controls are being installed. For specific OSHA
requirements on personal protective equipment, see OSHAs standard, 1910 Subpart I.
Personal protective equipment can be categorized by the area of the body protected, by the
types of hazard, and by the type of garment or accessory. A single item, for example boots, may
provide multiple forms of protection: a steel toe cap and steel insoles for protection of the feet
from crushing or puncture injuires, impervious rubber and lining for protection from water and
chemicals, high reflectivity and heat resistance for protection from radiant heat, and high
electrical resistivity for protection from electric shock. The protective attributes of each piece of
equipment must be compared with the hazards expected to be found in the workplace.

Engineering Controls

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Hierarchy of Controls

Controlling exposures to occupational hazards is the fundamental method of protecting workers.

Personal protective equipment

If feasible, design the facility, equipment, or process to remove the hazard or

If removal is not feasible, enclose the hazard to prevent exposure in normal

Where complete enclosure is not feasible, establish barriers or local ventilation to

Redesigning, changing, or substituting equipment to remove the source of excessive

Redesigning a process to use less toxic chemicals;

Complete enclosure of moving parts of machinery;

Complete containment of toxic liquids or gases;

Glove box operations to enclose work with dangerous microorganisms, radioisotopes, or

Complete containment of noise, heat, or pressure-producing processes.

Ventilation hoods in laboratory work;

Machine guarding, including electronic barriers;

Baffles used as noise-absorbing barriers; and

Nuclear radiation or heat shields.

Developing and implementing standard operating procedures.

Establishing and maintaining good housekeeping programs.

Keeping equipment well maintained.

Education and Training

Personal Protective Equipment (PPE)

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