Workplace Safety Risk Assessment and Site Hazard Identification Procedures

Assessment Date: [DATE]

Assessor: [ASSESSOR NAME]

Department/Area: [DEPARTMENT/AREA]

Review Date: [REVIEW DATE]

1. Assessment Scope

This risk assessment covers the identification, evaluation, and control of hazards associated with routine workplace activities, site inspections, task planning, and field-level job hazard analysis processes. It applies to employees, supervisors, contractors, and visitors who may be exposed to hazards during normal operations, non-routine tasks, and changing site conditions. The assessment includes real-time hazard recognition, selection of controls, safe systems of work, and verification that controls remain effective. It excludes detailed engineering design reviews, medical surveillance programs, and emergency response plans for site-specific major incidents unless those incidents are directly related to the hazards identified in this assessment.

2. Risk Assessment Methodology

A task-based job hazard analysis and field-level risk assessment methodology is used. Work activities are broken into discrete steps, hazards are identified for each step, and the likelihood and severity of harm are evaluated using a 5x5 risk matrix. Controls are selected using the hierarchy of controls, beginning with elimination and progressing through substitution, engineering controls, administrative controls, and personal protective equipment. Existing controls are reviewed for adequacy, additional controls are recommended where needed, and residual risk is reassessed after controls are applied. This approach aligns with the principle that hazards should be identified, assessed, and controlled before and during work, and that the assessment should be updated when conditions change.

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. Slips, trips, and falls on the same level caused by wet floors, uneven surfaces, poor housekeeping, trailing cables, or obstructed walkways.

Potential Consequences: Workers may suffer sprains, fractures, head injuries, or lost-time injuries. Visitors may also be affected if access routes are not kept clear.

Affected Persons: Employees, contractors, visitors, and any person moving through the work area.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Likely	Moderate	High

Control Measures

• Elimination: remove unnecessary obstacles and redesign workflow to avoid congestion in walkways.
• Substitution: use less slippery floor treatments or mats where appropriate.
• Engineering controls: install anti-slip flooring, cable covers, drainage improvements, and adequate lighting.
• Administrative controls: implement housekeeping standards, inspection routines, spill response procedures, and clear pedestrian routes.
• PPE: provide slip-resistant footwear where required by the task and site conditions.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Minor	Low

2. Falls from height during work on ladders, platforms, roofs, or elevated work areas.

Potential Consequences: A fall may result in serious injury, permanent disability, or fatality. Falling objects may also injure people below.

Affected Persons: Workers at height, workers below, contractors, and nearby visitors.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Catastrophic	Extreme

Control Measures

• Elimination: perform work from ground level whenever practicable.
• Substitution: use a scissor lift or elevating work platform instead of a ladder where suitable.
• Engineering controls: install guardrails, toe boards, anchor points, and fall arrest systems where required.
• Administrative controls: use a working-at-heights permit, pre-task briefing, inspection of access equipment, exclusion zones, and rescue planning.
• PPE: use a full body harness, lanyard, head protection, and suitable footwear when fall protection is required.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Major	Medium

3. Struck-by hazards from moving vehicles, mobile plant, forklifts, reversing equipment, or suspended loads.

Potential Consequences: Impact injuries may include crushing, fractures, internal injuries, or fatality. Property damage and secondary incidents may also occur.

Affected Persons: Operators, spotters, pedestrians, contractors, and visitors.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Catastrophic	Extreme

Control Measures

• Elimination: separate pedestrians from vehicle routes and avoid simultaneous work where possible.
• Substitution: use smaller or less hazardous equipment where task requirements allow.
• Engineering controls: install barriers, marked traffic routes, reversing alarms, mirrors, and physical segregation.
• Administrative controls: apply traffic management plans, trained spotters, speed limits, exclusion zones, and communication protocols.
• PPE: high-visibility clothing and task-appropriate protective footwear.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Major	Medium

4. Caught-in, caught-between, and entanglement hazards from unguarded machinery, rotating parts, pinch points, or moving components.

Potential Consequences: Workers may experience amputations, crushing injuries, lacerations, or fatal injuries.

Affected Persons: Machine operators, maintenance personnel, cleaners, and nearby workers.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Catastrophic	Extreme

Control Measures

• Elimination: remove the need for manual intervention where possible through automation or process redesign.
• Substitution: use safer tools or equipment with built-in safety features.
• Engineering controls: fit machine guards, interlocks, emergency stops, and physical barriers.
• Administrative controls: apply lockout/tagout procedures, safe operating procedures, maintenance isolation, and competency verification.
• PPE: use task-specific gloves, eye protection, and protective footwear where appropriate, noting PPE is not a substitute for guarding.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Rare	Major	Medium

5. Electrical hazards from exposed conductors, damaged cords, faulty equipment, temporary power supplies, or contact with live parts.

Potential Consequences: Electric shock, burns, arc flash injuries, equipment damage, fire, or fatality may occur.

Affected Persons: Electricians, maintenance staff, operators, contractors, and anyone using portable electrical equipment.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Catastrophic	Extreme

Control Measures

• Elimination: de-energize circuits before work and avoid live work unless strictly justified.
• Substitution: use low-voltage or battery-powered equipment where feasible.
• Engineering controls: install residual current protection, insulation, covers, and proper grounding.
• Administrative controls: apply permit-to-work, isolation verification, inspection of cords and plugs, and competent-person authorization.
• PPE: arc-rated clothing, insulated gloves, eye and face protection, and dielectric footwear as required by the task.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Rare	Major	Medium

6. Manual handling and ergonomic strain from lifting, carrying, pushing, pulling, repetitive work, or awkward postures.

Potential Consequences: Workers may develop strains, sprains, musculoskeletal disorders, fatigue, or reduced productivity.

Affected Persons: Warehouse staff, cleaners, maintenance workers, production workers, and delivery personnel.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Likely	Moderate	High

Control Measures

• Elimination: eliminate unnecessary manual handling by redesigning the task or process.
• Substitution: use mechanical aids such as trolleys, hoists, pallet jacks, or lift tables.
• Engineering controls: improve workstation layout, reduce reach distances, and provide adjustable work surfaces.
• Administrative controls: rotate tasks, set load limits, train on safe lifting techniques, and plan team lifts.
• PPE: use grip-enhancing gloves and supportive footwear where appropriate.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Minor	Medium

7. Exposure to hazardous substances such as cleaning chemicals, solvents, dusts, fumes, vapours, or process residues.

Potential Consequences: Exposure may cause skin irritation, respiratory effects, eye injury, poisoning, sensitisation, or long-term illness.

Affected Persons: Workers handling substances, nearby employees, contractors, and visitors in affected areas.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Major	High

Control Measures

• Elimination: remove hazardous substances from the process where possible.
• Substitution: replace with less hazardous products such as water-based or low-toxicity alternatives.
• Engineering controls: use local exhaust ventilation, closed transfer systems, and sealed containers.
• Administrative controls: maintain SDS access, labeling, spill procedures, hygiene rules, and exposure limits.
• PPE: chemical-resistant gloves, eye/face protection, respiratory protection, and protective clothing matched to the hazard.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Moderate	Medium

8. Fire and explosion hazards from flammable liquids, hot work, ignition sources, poor storage, or combustible dust accumulation.

Potential Consequences: Burns, smoke inhalation, structural damage, business interruption, and fatality may result.

Affected Persons: All site occupants, emergency responders, contractors, and nearby members of the public.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Catastrophic	High

Control Measures

• Elimination: remove ignition sources and unnecessary flammable materials from the work area.
• Substitution: use less flammable products or processes where feasible.
• Engineering controls: provide fire detection, suppression systems, ventilation, and approved storage cabinets.
• Administrative controls: hot work permits, housekeeping, segregation of combustibles, emergency drills, and inspection of extinguishers.
• PPE: flame-resistant clothing, gloves, eye protection, and respiratory protection where smoke exposure is possible.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Rare	Major	Medium

5. General Control Measures

• Implement a formal hazard reporting and inspection process to identify new or changing hazards before work starts and during the job.

Use pre-start inspections, field-level risk assessments, and immediate escalation of unsafe conditions so controls can be adjusted in real time.

• Require site-specific job briefings before work begins and whenever conditions change.

Review task steps, hazards, controls, emergency arrangements, and any site-specific risks not already captured in the assessment.

• Maintain a documented safe system of work for routine and non-routine tasks.

Include task steps, permits, isolation requirements, communication methods, supervision arrangements, and stop-work authority.

• Apply the hierarchy of controls consistently and do not rely on PPE as the primary control where higher-level controls are reasonably practicable.

Use elimination and substitution first, then engineering controls, then administrative controls, with PPE as the final layer of protection.

• Ensure equipment, tools, and protective devices are inspected, maintained, and removed from service when defective.

Include pre-use checks, scheduled maintenance, defect tagging, and replacement of damaged items before further use.

6. Emergency Preparedness

• Establish written emergency procedures for falls, electrical incidents, chemical exposure, fire, vehicle strikes, and serious injury, and ensure workers know how to raise the alarm and summon assistance.
• Provide and maintain suitable emergency equipment such as first aid supplies, spill kits, fire extinguishers, eyewash facilities, rescue equipment for work at height, and communication devices.
• Train workers to stop work, isolate hazards where safe, evacuate affected areas, and account for personnel during emergencies or drills.
• Practice emergency response regularly so workers can respond effectively to unplanned events such as spills, fires, releases, injuries, or rescue situations.
• Ensure rescue arrangements are specific to the task, especially for work at height, confined spaces, or other situations where delayed rescue could worsen injury.

7. Training Requirements

• Job Hazard Analysis and Field-Level Risk Assessment Training: Workers and supervisors must be trained to break tasks into steps, identify hazards, evaluate likelihood and severity, and select controls using the hierarchy of controls. Training should emphasize that the assessment is a living document and must be updated when conditions change.
  • How to identify task steps
  • How to recognize obvious and hidden hazards
  • How to assign risk ratings consistently
  • How to escalate unresolved hazards before work proceeds
• Hierarchy of Controls Training: Personnel must understand the order of control preference and why elimination and substitution are more effective than administrative controls or PPE. Training should include practical examples relevant to the site.
  • Elimination
  • Substitution
  • Engineering controls
  • Administrative controls
  • PPE as the last line of defense
• Task-Specific Safe Work Procedure Training: Employees must be trained on the approved method of work for their tasks, including permits, isolation steps, equipment setup, communication requirements, and stop-work authority. Competency should be verified before independent work is allowed.
  • Permit-to-work requirements
  • Lockout/tagout or isolation steps
  • Use of access equipment
  • Traffic management and exclusion zones
• PPE Selection, Use, and Limitations Training: Workers must be trained to select, wear, inspect, maintain, and replace PPE that matches the hazard. Training must also explain the limitations of PPE and the need for higher-level controls wherever practicable.
  • Correct fit and adjustment
  • Inspection before use
  • Cleaning and storage
  • When to replace damaged PPE
• Emergency Response and Incident Reporting Training: Workers must know how to respond to spills, fires, injuries, electrical incidents, and falls, including alarm activation, evacuation, first aid notification, and incident reporting. Training should include practical drills and scenario-based exercises.
  • Emergency contacts and alarm methods
  • Evacuation routes and assembly points
  • First aid and rescue arrangements
  • Near-miss and hazard reporting

8. Monitoring and Review

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

Monitoring Type	Frequency	Responsible Party	Description
Regular Inspection	Daily before work and during task execution	Supervisors and task leaders	Inspect the work area, equipment, access routes, and controls before work starts and throughout the shift to identify changing hazards, damaged equipment, or unsafe conditions.
Control Effectiveness Review	Weekly	Supervisors with worker participation	Review whether implemented controls are reducing exposure as intended, including housekeeping, guarding, traffic segregation, ventilation, and PPE compliance.
Formal Workplace Inspection	Quarterly	Trained safety personnel and management representatives	Conduct documented inspections to identify new hazards, verify corrective actions, and confirm that control measures remain suitable after changes to equipment, materials, or processes.
Incident and Near-Miss Trend Review	Monthly	Safety manager and line management	Analyze injuries, illnesses, near misses, and hazard reports to identify recurring hazards, weak controls, and opportunities for improvement.
Risk Assessment Review	Annually and after any significant change, incident, or near miss	Management and competent supervisors	Review and update the assessment whenever work methods, equipment, materials, staffing, weather exposure, or site conditions change, or when an incident indicates controls are no longer adequate.

9. Special Circumstances

• Adverse weather such as rain, ice, snow, high winds, heat, or poor visibility can increase slip, vehicle, working-at-height, and heat-stress risks and may require work postponement or additional controls.
• Night work or low-light conditions increase the likelihood of slips, struck-by incidents, and poor hazard recognition, so lighting, supervision, and communication controls must be strengthened.
• Lone work increases response time in an emergency and requires enhanced communication checks, check-in procedures, and clear escalation arrangements.
• Non-routine or infrequently performed tasks may present unfamiliar hazards and should be subject to a fresh task briefing and review before work begins.
• Changes in equipment, materials, staffing, or work sequence can introduce new hazards and require the risk assessment to be revised before continuing work.

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, significant change, or change in site conditions. or when significant changes occur.

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