Hazard Analysis: Identification, Assessment & Controls
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Hazard analysis is the systematic process of identifying things in the workplace that can cause harm, evaluating the risk they pose, and determining the controls needed to protect workers. It is the foundation of every effective safety program, from a single Job Safety Analysis to a facility-wide safety management system.
Workplace hazards come in many forms: unguarded machinery, toxic chemicals, fall exposures, electrical sources, extreme temperatures, repetitive motions, and biological agents. Each has a different risk profile and requires different controls. A fall from elevation and a chemical splash both injure workers, but the analysis process, the applicable OSHA standards, and the control strategies are entirely different.
The guides below cover 20 of the most common and consequential workplace hazards. Each includes OSHA standards and citation data, control strategies organized by the hierarchy of controls, affected industries, required PPE, and answers to frequently asked questions.
Disclaimer
This content is provided for general informational and educational purposes only. It is not a substitute for a site-specific Job Safety Analysis conducted by a qualified safety professional familiar with your workplace conditions, equipment, and personnel. OSHA citations, BLS statistics, and hazard controls referenced here may not reflect the most current standards or apply to your specific situation. Always consult current OSHA regulations, manufacturer guidelines, and a competent person before beginning work. Health & Safety Systems LLC assumes no liability for actions taken based on this content.
Hierarchy of Controls
The hierarchy of controls is the universally accepted framework for selecting hazard controls. It ranks control methods from most to least effective. Controls higher on the hierarchy are more reliable because they reduce or remove the hazard itself, rather than depending on workers to protect themselves.
1 Elimination — Physically remove the hazard. Most effective because the hazard ceases to exist. Example: redesign a process to eliminate work at height.
2 Substitution — Replace with something less dangerous. Example: water-based solvent instead of a VOC, scissor lift instead of a ladder.
3 Engineering Controls — Isolate workers from the hazard with physical solutions. Example: guardrails, local exhaust ventilation, machine guards.
4 Administrative Controls — Change how people work through procedures, training, and signage. Less reliable because they depend on human behavior. Example: lockout/tagout procedures, confined space permits.
5 PPE — The last line of defense. Protects the individual but does not reduce the hazard itself. Example: hard hats, respirators, fall harnesses, gloves.
Every hazard analysis guide on this site organizes controls by this hierarchy. When building a JSA, always start at the top and work down. The best safety programs eliminate hazards where possible and layer multiple controls where elimination is not feasible.
Hazard Analysis Guides
Select a hazard below to view a detailed analysis with OSHA standards, control strategies, affected industries, and required PPE.
Atmospheric
Biological
Chemical
Electrical
Energy Control
Environmental
Ergonomic
Falls
Fire
Mechanical
Radiation
Structural
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Start Free TrialOSHA's Role in Hazard Analysis
OSHA does not mandate a single "hazard analysis" standard that covers all workplaces. Instead, hazard analysis requirements are embedded throughout OSHA's regulatory framework:
- PPE Hazard Assessment (29 CFR 1910.132(d)): Requires employers to assess the workplace for hazards that necessitate PPE. This is the most broadly applicable hazard analysis requirement in general industry.
- Process Hazard Analysis (29 CFR 1910.119): Requires facilities with highly hazardous chemicals to conduct a process hazard analysis (PHA) using recognized methodologies such as What-If, HAZOP, or Fault Tree Analysis.
- Permit-Required Confined Spaces (29 CFR 1910.146): Requires hazard evaluation and atmospheric monitoring before entry into permit-required confined spaces.
- Job Hazard Analysis (OSHA 3071): While not a regulation, this publication provides OSHA's recommended methodology for task-level hazard analysis. It is the basis for the JSA/JHA process used across industries.
- General Duty Clause (Section 5(a)(1)): Requires employers to provide a workplace free from recognized hazards. Hazard analysis is the primary method for identifying recognized hazards and documenting controls.
OSHA's enforcement data shows clear patterns in which hazards generate the most citations. Falls, hazardous communication, respiratory protection, lockout/tagout, and scaffolding consistently rank in the top 10 most cited standards. The individual hazard guides on this site include citation data for each relevant OSHA standard.
Related Resources
Frequently Asked Questions
▶ What is hazard analysis?
Hazard analysis is the systematic process of identifying workplace hazards, assessing the risk they pose to workers, and determining controls to eliminate or reduce that risk. It is the foundation of all workplace safety programs. Hazard analysis can be conducted at the job level (JSA/JHA), the process level (PHA), or the facility level (comprehensive safety audit). The goal is always the same: find what can hurt people and fix it before it does.
▶ What is the hierarchy of controls?
The hierarchy of controls is a five-level framework for selecting the most effective hazard controls. From most to least effective: (1) Elimination — physically remove the hazard. (2) Substitution — replace the hazard with something less dangerous. (3) Engineering controls — isolate people from the hazard with guards, ventilation, barriers, etc. (4) Administrative controls — change the way people work through procedures, training, and signage. (5) PPE — protect the worker with personal protective equipment. Controls higher on the hierarchy are more reliable because they don't depend on worker behavior.
▶ What is the difference between a hazard and a risk?
A hazard is anything that has the potential to cause harm: a chemical, an unguarded machine, a height, an electrical source. Risk is the combination of how likely the hazard is to cause harm and how severe that harm would be. Hazard analysis identifies the hazards; risk assessment evaluates the risk they pose. Controls are then selected to reduce risk to an acceptable level.
▶ How does OSHA require hazard analysis?
OSHA does not have a single standard requiring "hazard analysis" as a standalone activity. However, many OSHA standards require specific types of hazard assessment: the PPE standard (29 CFR 1910.132) requires a hazard assessment to select appropriate PPE, the Process Safety Management standard (29 CFR 1910.119) requires a process hazard analysis, and the Permit-Required Confined Spaces standard requires hazard evaluation before entry. The General Duty Clause (Section 5(a)(1)) also implicitly requires employers to identify recognized hazards.
▶ What are the most common workplace hazards?
OSHA groups workplace hazards into six categories: (1) Safety hazards — falls, struck-by, caught-in, electrical contact. (2) Chemical hazards — toxic substances, flammable materials, corrosives. (3) Biological hazards — bloodborne pathogens, mold, infectious agents. (4) Physical hazards — noise, radiation, temperature extremes. (5) Ergonomic hazards — repetitive motion, awkward postures, heavy lifting. (6) Psychosocial hazards — workplace violence, stress, fatigue. The most common causes of workplace fatalities are falls, struck-by incidents, electrocutions, and caught-in/between incidents (OSHA's "Fatal Four").
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