Personal Safety Hazards Risk Assessment

Assessment Date: [DATE]

Assessor: [ASSESSOR NAME]

Department/Area: [DEPARTMENT/AREA]

Review Date: [REVIEW DATE]

1. Assessment Scope

This risk assessment covers routine workplace activities where employees may be exposed to personal safety hazards, including slips, trips, falls, struck-by hazards, cuts, manual handling injuries, electrical contact, noise exposure, chemical contact, and exposure to airborne contaminants. The assessment applies to normal operations, setup, cleaning, inspection, maintenance, and material handling tasks performed by employees, contractors, and any other persons who may be present in the work area. It includes hazard identification, risk evaluation, control selection, PPE requirements, safe working procedures, residual risk, emergency preparedness, monitoring, and review requirements. Exclusions: this assessment does not replace task-specific permits, confined space assessments, lockout/tagout procedures, or specialized assessments for high-risk activities unless those activities are specifically included in a separate task analysis.

2. Risk Assessment Methodology

A baseline survey and task-based job hazard analysis approach were used to identify hazards, evaluate exposure, and determine suitable controls. Each hazard was assessed using a 5x5 risk matrix considering likelihood and severity, with risk ratings expressed as Low, Medium, High, or Extreme. Controls were selected using the hierarchy of controls, prioritizing elimination, substitution, engineering controls, administrative controls, and PPE as the last line of defense. PPE selection follows the principle that hazards should be controlled by engineering and work practice measures before relying on PPE. [8] [4] [14]

3. Risk Matrix Reference

The following matrix is used to evaluate risk levels based on likelihood and severity:

		Likelihood
Rare	Unlikely	Possible	Likely	Almost Certain
Severity	Catastrophic	Low	Low	Low	Medium	Medium
Major	Low	Low	Medium	Medium	High
Moderate	Low	Medium	Medium	High	High
Minor	Medium	Medium	High	High	Extreme
Negligible	Medium	High	High	Extreme	Extreme

4. Hazard Identification and Risk Evaluation

1. Moving machinery, rotating parts, and pinch points during equipment operation, setup, and stock handling.

Potential Consequences: Fingers, hands, or clothing may be caught in moving parts, resulting in cuts, punctures, fractures, amputations, or entanglement injuries. [2] [2] [4]

Affected Persons: Operators, helpers, maintenance personnel, and nearby workers.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Major	High

Control Measures

• Eliminate exposure by stopping and isolating equipment before adjustments, cleaning, or stock changes.
• Substitute manual handling methods with safer mechanical aids where feasible.
• Install fixed or interlocked guards at points of operation and moving components.
• Use lockout/tagout and safe work procedures for maintenance and jam clearing.
• Provide task-specific training and prohibit loose clothing, jewelry, and unsecured hair.
• Require appropriate hand protection only where it does not increase entanglement risk and is compatible with the task.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Major	Medium

2. Flying particles, chips, dust, or fragments generated by cutting, grinding, drilling, or impact tasks.

Potential Consequences: Eye injuries, facial lacerations, skin irritation, and secondary injuries from loss of vision or distraction. [2] [5] [10]

Affected Persons: Operators, helpers, maintenance staff, and nearby persons.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Likely	Moderate	High

Control Measures

• Eliminate or reduce particle generation by using lower-energy methods where practical.
• Install machine guards, chip shields, or local containment barriers.
• Use tools and processes that minimize ejection of material.
• Establish exclusion zones and keep bystanders clear of the work area.
• Require safety glasses with side shields and task-appropriate face protection.
• Maintain good housekeeping to prevent re-entrainment of debris and to keep visibility clear.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Minor	Low

3. Manual handling of heavy, awkward, or unstable loads during lifting, carrying, pushing, pulling, or stacking.

Potential Consequences: Sprains, strains, back injuries, crush injuries to feet or hands, and dropped-load incidents. [5] [5] [2]

Affected Persons: Workers handling materials, helpers, and persons in the load path.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Likely	Moderate	High

Control Measures

• Eliminate unnecessary manual lifting by redesigning the workflow.
• Substitute smaller or lighter loads where possible.
• Use hoists, carts, pallet jacks, lift tables, or other mechanical aids.
• Train workers in safe lifting, team lifting, and load planning.
• Set weight limits and require assessment of load stability before movement.
• Require safety footwear and gloves suitable for the material being handled.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Minor	Medium

4. Slips, trips, and falls on the same level caused by wet floors, clutter, uneven surfaces, cords, or poor housekeeping.

Potential Consequences: Bruises, fractures, head injuries, sprains, and lost-time incidents.

Affected Persons: All workers, visitors, contractors, and delivery personnel.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Likely	Moderate	High

Control Measures

• Eliminate trip hazards by removing unnecessary materials, cords, and waste from walkways.
• Improve drainage, floor condition, and surface repairs where needed.
• Use slip-resistant flooring or mats in wet or high-traffic areas.
• Implement housekeeping standards and immediate spill cleanup procedures.
• Provide adequate lighting and clearly mark changes in level or walking routes.
• Require slip-resistant footwear where conditions warrant it.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Minor	Medium

5. Exposure to electrical energy from damaged cords, faulty equipment, improper use of portable tools, or contact with energized parts.

Potential Consequences: Electric shock, burns, arc flash injuries, fire, and secondary trauma from falls or startle response. [10] [10] [12]

Affected Persons: Operators, maintenance personnel, electricians, and nearby workers.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Catastrophic	Extreme

Control Measures

• Eliminate exposure by de-energizing equipment before work begins.
• Substitute battery-powered or low-voltage tools where practical.
• Inspect cords, plugs, and equipment before use and remove defective items from service.
• Use qualified persons for electrical work and apply lockout/tagout where required.
• Maintain covers, enclosures, and grounding systems in good condition.
• Provide electrical PPE and arc-rated protection only for tasks where exposure cannot be eliminated.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Rare	Major	Medium

6. Noise exposure from machinery, tools, compressors, or repetitive high-noise operations.

Potential Consequences: Temporary or permanent hearing loss, tinnitus, communication failure, and reduced situational awareness. [2] [11] [11] [11]

Affected Persons: Operators, maintenance staff, and persons working near noisy equipment.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Likely	Moderate	High

Control Measures

• Eliminate or reduce noise at the source through quieter equipment selection.
• Substitute lower-noise tools or processes where feasible.
• Install acoustic enclosures, barriers, dampening, or isolation mounts.
• Limit exposure time through job rotation and scheduling.
• Post hearing protection zones and require hearing protection where exposure levels warrant it.
• Conduct noise monitoring and maintain a hearing conservation program where required.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Minor	Medium

7. Contact with hazardous chemicals, including cleaning agents, coolants, lubricants, solvents, or process chemicals.

Potential Consequences: Skin irritation, dermatitis, chemical burns, eye injury, respiratory irritation, sensitization, or systemic illness. [2] [2] [10] [10]

Affected Persons: Workers handling chemicals, maintenance staff, cleaners, and nearby persons exposed to splashes or vapors.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Major	High

Control Measures

• Eliminate unnecessary chemical use and substitute less hazardous products where possible.
• Use closed transfer systems, local exhaust ventilation, and splash containment.
• Store, label, and segregate chemicals correctly and maintain current safety data sheets.
• Train workers on safe handling, dilution, spill response, and first aid.
• Require chemical-resistant gloves, eye protection, face protection, and other PPE appropriate to the chemical.
• Restrict access to authorized personnel where higher-risk chemicals are used.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Moderate	Medium

8. Exposure to airborne contaminants such as dust, fumes, mist, vapors, or oxygen-deficient atmospheres during certain tasks.

Potential Consequences: Respiratory irritation, occupational illness, reduced oxygen intake, dizziness, unconsciousness, or long-term health effects. [13] [13] [9]

Affected Persons: Workers performing the task, nearby workers, and emergency responders.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Major	High

Control Measures

• Eliminate the source of airborne contaminants where feasible.
• Substitute less hazardous materials or processes.
• Use local exhaust ventilation, general ventilation, or isolation controls.
• Monitor airborne exposure where required and compare results to applicable limits.
• Implement respiratory protection only when engineering and administrative controls are insufficient.
• Ensure respirators are selected, fit-tested, and used in accordance with the hazard and exposure conditions.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Moderate	Medium

5. General Control Measures

• Maintain a documented hazard assessment process for all relevant tasks and update it when equipment, materials, processes, or work locations change.

Use baseline surveys and task-based reviews to identify new or changing hazards before work begins or after changes occur. [3] [6]

• Apply the hierarchy of controls before relying on PPE.

Prioritize elimination, substitution, engineering controls, and administrative controls; use PPE as the final layer of protection. [4] [7]

• Provide and enforce task-specific PPE selection, fit, use, inspection, and replacement.

Match PPE to the hazard, ensure it fits the wearer, and remove damaged or worn PPE from service immediately. [12] [12] [7]

• Implement housekeeping, access control, and clear communication standards across the site.

Keep walkways clear, control bystander access, post warning signs where needed, and ensure workers understand area-specific hazards.

• Ensure supervisors verify safe work practices and intervene when unsafe conditions or behaviors are observed.

Use routine field observations, corrective action tracking, and stop-work authority for uncontrolled hazards. [7]

6. Emergency Preparedness

• Establish first aid and emergency response procedures for cuts, crush injuries, eye injuries, burns, electrical shock, and chemical exposure. Ensure workers know how to summon help, isolate the hazard, and provide immediate care within their training level.
• Provide eyewash and emergency washing capability where chemical splash or particulate exposure is possible, and ensure access routes remain unobstructed at all times.
• Develop spill response procedures for chemical releases, including area isolation, ventilation, cleanup by trained personnel, and escalation criteria for larger or unknown spills.
• Prepare electrical emergency procedures that include de-energizing equipment only by qualified persons, contacting emergency services when shock or fire occurs, and prohibiting contact with energized victims until the source is isolated.
• Maintain evacuation and communication procedures for fire, severe injury, airborne contaminant release, or any event that creates an immediate danger to life or health.

7. Training Requirements

• Hazard Recognition and Risk Awareness: Train workers to identify personal safety hazards associated with their tasks, recognize warning signs of unsafe conditions, and understand the consequences of exposure. Training should include how to report hazards, near misses, and equipment defects promptly.
  • Task-specific hazard identification
  • Stop-work expectations
  • Reporting and escalation procedures
• PPE Selection, Use, and Limitations: Train employees on the correct PPE for each task, how to wear it properly, how to inspect it before use, and when it must be replaced. Training must also explain the limitations of PPE and why it does not replace engineering or administrative controls. [1] [7] [7]
  • Correct donning and doffing
  • Fit and compatibility with other PPE
  • Inspection, cleaning, storage, and replacement
• Safe Manual Handling and Material Movement: Train workers in safe lifting techniques, team lifting, use of mechanical aids, load stability checks, and safe travel paths. Emphasize foot protection, hand protection, and keeping the load path clear.
  • Use of hoists, carts, and pallet jacks
  • Weight and stability assessment
  • Safe stacking and transport
• Chemical Safety and Spill Response: Train workers who handle chemicals on label reading, safety data sheet use, safe mixing and transfer, exposure prevention, and spill response. Include emergency washing procedures and the correct selection of chemical-resistant PPE. [8] [10]
  • SDS review
  • Chemical compatibility and storage
  • First aid for splash or contact exposure
• Electrical and Equipment Safety: Train authorized personnel on equipment isolation, lockout/tagout principles, pre-use inspection, and the hazards of energized parts. Workers must understand when to stop work and request qualified assistance.
  • Pre-use inspection of cords and tools
  • Isolation before maintenance
  • Qualified-person requirements

8. Monitoring and Review

Review Frequency: Annually and after any incident, near miss, equipment change, process change, or significant change in work conditions.

Monitoring Type	Frequency	Responsible Party	Description
Regular Inspection	Daily before use and during work shifts	Supervisors and equipment operators	Inspect tools, equipment, guards, PPE, walkways, and work areas for defects, damage, obstructions, leaks, and unsafe conditions. Remove defective items from service immediately. [7] [7]
Workplace Hazard Survey	Quarterly and whenever processes, equipment, or materials change	Trained supervisors or safety personnel	Review the workplace for new or changed hazards, verify controls remain effective, and update the hazard assessment when conditions change. [3] [6]
PPE Compliance Check	Weekly and during spot checks	Supervisors	Verify that required PPE is selected correctly, worn consistently, maintained in good condition, and replaced when damaged or worn. [12]
Exposure Monitoring	As needed based on hazard and regulatory requirements	Safety personnel or qualified industrial hygiene support	Measure noise, airborne contaminants, or other exposures where there is potential for overexposure and compare results to applicable limits or internal action levels. [11] [13]
Incident and Near-Miss Review	After every incident or near miss	Management and safety leadership	Investigate incidents and near misses to determine root causes, verify control failures, and implement corrective actions to prevent recurrence.

9. Special Circumstances

• Weather conditions such as rain, ice, heat, wind, or poor visibility can increase slip, trip, fall, heat stress, and struck-by risks. Work should be paused or modified when conditions make controls ineffective.
• Night work or low-light conditions increase the likelihood of slips, trips, vehicle interface incidents, and reduced hazard recognition. Additional lighting, supervision, and communication controls are required.
• Lone work increases the severity of incidents because immediate assistance may be delayed. Lone workers should have check-in procedures, communication devices, and clear escalation triggers.
• Fatigue, time pressure, and extended shifts can reduce attention and increase error rates. Supervisors should manage workload, rest breaks, and task rotation to reduce exposure.
• Temporary work areas, contractors, and simultaneous operations can introduce unfamiliar hazards and interface risks. Coordination, induction, and area control measures are required before work starts.

Approval and Sign-off

This risk assessment has been reviewed and approved by:

Assessor: _________________________ Date: __________

Manager/Supervisor: _________________________ Date: __________

Safety Representative: _________________________ Date: __________

This risk assessment must be reviewed annually and after any incident, near miss, equipment change, process change, or significant change in work conditions. or when significant changes occur.

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