10 minutes estimated reading time.

Key takeaways:

• The hierarchy of control is a proven method for reducing workplace hazards.
• It prioritises elimination and substitution over PPE for lasting impact.
• Real-life examples from Australian industries show how it’s applied effectively.
• Using the hierarchy can reduce injuries, boost productivity, and meet legal safety duties.
• Understanding each level helps you create a safer, more resilient workplace.

Introduction

Every workplace has risks. But not all safety measures offer the same level of protection. That’s where the hierarchy of control measures comes in.

This widely used model ranks control strategies from most to least effective. It helps businesses focus on long-term solutions—not just quick fixes. Whether you’re on a construction site, in an office, or working remotely, applying the right level of control can prevent injury and even save lives.

Let’s break down each level of the hierarchy and look at real examples from Australian workplaces.

What Is the Hierarchy of Control Measures?

The hierarchy of control is a risk management tool used to eliminate or reduce hazards. It’s a legal requirement under the Work Health and Safety (WHS) laws in Australia.

Here’s the control hierarchy from highest to lowest effectiveness:

1. Elimination – Remove the hazard completely.
2. Substitution – Replace the hazard with something safer.
3. Engineering Controls – Isolate people from the hazard.
4. Administrative Controls – Change the way people work.
5. Personal Protective Equipment (PPE) – Use equipment to reduce exposure.

The higher you go up the hierarchy, the more reliable the control. Let’s now see how this works in the real world.

1. Elimination: The Most Effective Control

Definition: Completely removing the hazard so it no longer poses any risk.

Example: Removing Asbestos from Buildings

In government buildings across NSW, asbestos removal programs have aimed to eliminate this deadly hazard entirely. Instead of managing the risk with signage and PPE, workers remove and dispose of asbestos under strict environmental and WHS protocols.

Other Examples:

• Discontinuing a dangerous chemical process.
• Using cordless tools to remove tripping hazards from power leads.
• Removing a broken ladder rather than continuing to repair it.

Why It Works:

Elimination stops the risk at the source. There’s no need for ongoing maintenance, monitoring, or worker compliance.

2. Substitution: Swap It for Something Safer

Definition: Replace a hazardous item or task with a safer alternative.

Example: Solvent Replacement in Automotive Workshops

Workshops often use harsh degreasers and cleaning agents. Some have switched to citrus-based, non-toxic solvents that reduce skin and respiratory irritation.

Other Examples:

• Using battery-powered forklifts instead of diesel-powered ones to reduce emissions.
• Replacing manual lifting tasks with vacuum lifters or trolleys.
• Swapping a noisy diesel generator with a quieter electric model.

When to Use It:

If you can’t eliminate a hazard, substitution is the next best option.

3. Engineering Controls: Isolate the Hazard

Definition: Use physical means to separate people from danger.

Example: Machine Guards in Manufacturing

In metal fabrication factories, workers operate heavy presses and cutting tools. By installing interlocked guards that stop machines when opened, operators are protected from moving parts.

Other Examples:

• Installing barriers around forklifts to separate them from pedestrian walkways.
• Using exhaust ventilation to remove dust or fumes.
• Introducing soundproof booths for noisy equipment.

What It Achieves:

Engineering controls don’t rely on behaviour—they create safer environments by design.

4. Administrative Controls: Change How Work Is Done

Definition: Introduce rules, training, or procedures to minimise risk.

Example: Rotating Workers to Prevent Heat Stress

In mining operations across WA, workers are exposed to extreme heat. Companies often apply job rotation and enforced hydration breaks to manage the risk of heat stroke.

Other Examples:

• Safety signage reminding workers to wear protective gear.
• Inductions and safety briefings for new employees.
• Implementing fatigue management policies for shift workers.

Limitations:

Administrative controls can reduce risk—but only when people follow them. That’s why training and supervision are critical.

5. Personal Protective Equipment (PPE): The Last Line of Defence

Definition: Use gear to protect individuals from hazards.

Example: Respirators in Construction Demolition

During demolition jobs, workers may be exposed to silica dust. Wearing P2 respirators, gloves, and goggles helps reduce inhalation and contact.

Other Examples:

• Hard hats, steel-toe boots, and high-vis clothing.
• Hearing protection in noisy environments.
• Gloves and aprons in food handling.

Reality Check:

PPE is essential, but it should never be the only control. It’s most effective when used with other controls higher up the hierarchy.

Real-World Scenario: Applying All Five Levels Together

Industry: Manufacturing – Metal Cutting Workshop

Hazard:

Fine metal dust causing respiratory issues.

Controls Applied:

Control Level	Action Taken
Elimination	Identified unnecessary cutting tasks and removed them.
Substitution	Replaced cutting discs with low-dust alternatives.
Engineering Control	Installed local exhaust ventilation and enclosed cutting area.
Administrative Control	Trained staff in safe use, created dust-cleanup protocols, and staggered shifts.
PPE	Provided P2 masks, eye protection, and overalls.

This layered approach ensures safety even if one control fails.

Table: Comparing the Control Measures

Control Level	Example	Reliability	Requires Worker Compliance
Elimination	Remove asbestos	Very High	No
Substitution	Switch to less toxic solvent	High	Minimal
Engineering Controls	Machine guards, barriers	High	Minimal
Administrative Controls	Job rotation, safety policies	Medium	High
PPE	Gloves, goggles, respirators	Low	Very High

Why the Hierarchy Matters in Australia

Australian WHS laws expect businesses to use the hierarchy when controlling risks. The Model Work Health and Safety Regulations state that higher-order controls must be considered before moving to PPE.

If you skip straight to PPE without considering elimination or substitution, you’re likely breaching your legal duty of care.

How to Use the Hierarchy of Controls in Your Workplace

Here’s a quick checklist:

1. Identify the hazard – What could cause harm?
2. Assess the risk – How likely and severe is the outcome?
3. Apply the hierarchy – Start at elimination and work your way down.
4. Implement the control – Use appropriate tools, systems, or equipment.
5. Monitor and review – Ensure controls remain effective over time.

Conclusion

Workplace safety isn’t just about ticking boxes. It’s about making meaningful changes that protect lives. The hierarchy of control measures gives you a practical way to do that.

Whether you’re in HR, operations, or health and safety, understanding this model helps you meet your legal obligations and build a safer workplace.

Frequently Asked Questions (FAQs)

1. Can you use more than one control at once?

Yes, and in most cases, using multiple controls together is the safest approach. The hierarchy of control is not about choosing just one method—it’s about starting with the most effective option and layering others where necessary. For example, in a manufacturing environment, you might eliminate unnecessary tasks, substitute hazardous materials, add engineering controls like guards or ventilation, implement administrative protocols such as training and supervision, and still require PPE as a backup. This multi-layered system ensures that if one control fails, others still provide protection.

2. Why isn’t PPE enough?

PPE is the least effective method because it doesn’t eliminate the hazard—only reduces a person’s exposure to it. It relies heavily on correct and consistent use, which is subject to human error, fatigue, and comfort levels. If a worker removes their respirator or forgets their gloves, they’re immediately exposed to risk. Unlike engineering controls or elimination, PPE does not stop the hazard from occurring; it only shields the individual. That’s why it should always be the last resort, used only when higher-level controls can’t fully eliminate or reduce the hazard.

3. What’s an example of substitution in an office?

Substitution in an office setting might involve replacing harsh chemical cleaning agents with low-toxicity, plant-based alternatives to reduce respiratory irritation or allergic reactions among staff. Another example is swapping fluorescent lighting, which may cause eye strain or migraines, with LED lights that produce a softer and more consistent glow. These changes may seem minor, but they significantly improve indoor air quality and comfort, reducing absenteeism and boosting employee well-being without altering productivity or workflow.

4. How do I know which control to apply?

The best control depends on the level of risk and the nature of the hazard. Start by conducting a formal risk assessment to evaluate how likely an incident is to occur and how severe the outcome could be. Use this assessment to prioritise elimination or substitution if feasible. If those aren’t practical, move down the hierarchy, implementing engineering and administrative controls, then PPE. Remember, WHS legislation in Australia requires businesses to consider higher-level controls before relying on lower-level options. Regular reviews should also be conducted to ensure the selected controls remain effective over time.

5. Who is responsible for applying the hierarchy?

In Australia, the responsibility for applying the hierarchy of control falls on the Person Conducting a Business or Undertaking (PCBU), as defined in WHS legislation. This includes business owners, employers, or any person with management or control over a workplace. They must ensure that risks are eliminated or minimised using the most effective methods reasonably practicable. While managers, team leaders, and health and safety officers may assist in applying and monitoring controls, the PCBU holds the legal duty to provide a safe work environment and ensure ongoing compliance with WHS requirements.