The hierarchy of controls ranks safety measures in order of effectiveness, starting with the most impactful—eliminating hazards altogether—and ending with personal protective equipment (PPE). Using this approach, safety managers can prioritise long-term, sustainable solutions over temporary fixes or workarounds, ensuring that risks are controlled at their source whenever possible.
We’re going to look at each level of the hierarchy in more detail, along with how these principles are applied in the high-risk sectors that Flare serves.
At the top of the hierarchy is elimination – and with good reason! If you can remove a hazard entirely, you've effectively wiped out any associated risks. This is the most effective control because it leaves no room for error – if the hazard doesn’t exist, neither does the risk.
In theory, this sounds simple. But in practice, it’s not always feasible. This is particularly true in industries like oil and gas, where hazards are often inherent to the work being done. For example, an oil rig where hazardous gases are part of the process: eliminating those gases wouldn’t be possible without eliminating the entire operation. However, elimination can often be applied at the design phase of a project, where safer alternatives can be built into the blueprint from the outset.
Consider the early stages of an offshore platform's design. Engineers may be able to eliminate the need for a particularly dangerous chemical by selecting alternative materials or modifying processes. In other cases, dangerous tasks that previously required human involvement can be redesigned to be automated or performed remotely, effectively eliminating the hazard to personnel.
Elimination is the most powerful tool in the hierarchy, but it’s not always possible, especially in complex environments. When it is possible, it should be the first step in any risk management plan.
If you can’t get rid of a hazard, the next best option is to substitute it with something less hazardous. Substitution is a viable strategy in many situations but, like elimination, it works best in the planning stages of a project when materials, equipment, or processes are still flexible. Substitution can take many forms: replacing toxic chemicals with less harmful ones, swapping out older equipment for newer, safer models, or even altering work procedures to minimise risk exposure.
In the context of QHSE, substitution might involve using materials that are less flammable or reactive. For example, a ship's maintenance crew might switch from a solvent with high volatile organic compounds (VOCs) to one with a lower toxicity profile, significantly reducing the risk of harmful exposure. Or, in fire protection systems, engineers might replace traditional suppression agents with environmentally friendly alternatives that pose less risk to personnel and ecosystems alike.
The challenge with substitution is ensuring that the alternative doesn't introduce any new risks to the situation. It's essential to evaluate both the current hazard and the potential consequences of its replacement. A poorly considered substitution could solve one problem but create another. For instance, switching to a less toxic chemical might reduce health risks but increase operational inefficiencies if the new chemical is less effective, requiring more frequent application or larger quantities.
That’s where experience and expertise come into play. At Flare, our design and engineering teams work closely with clients to find solutions that not only reduce risks but also optimise performance. By looking at the bigger picture, we help ensure that substitutions make operations safer without sacrificing efficiency.
Engineering controls sit firmly in the middle of the hierarchy. These involve physically altering the workplace or the way tasks are performed to reduce exposure to hazards. Unlike elimination or substitution, which deal with the hazard at its source, engineering controls work by isolating people from the risk. These are often more sustainable than administrative measures because they don't rely on human behaviour for their effectiveness – they are built into the system.
In practice, engineering controls can take many forms, from ventilation systems that remove hazardous fumes, to barriers that keep workers at a safe distance from dangerous machinery. In the offshore sector, you’ll often see sophisticated engineering controls used to manage the risks associated with fire and explosions. For instance, blast walls are a common engineering control on oil rigs, designed to protect workers from the force of an explosion in the event of a gas leak.
Another example comes from Flare’s fire protection services, where bespoke fire suppression systems are designed and engineered to control the spread of fire in high-risk environments. These systems can be installed in key areas, like engine rooms or critical operational hubs, to minimise damage and protect personnel if a fire breaks out. Because these controls are integrated into the infrastructure, they require minimal ongoing intervention once in place, making them a reliable and effective long-term solution.
In our work with clients in hazardous environments, engineering controls are often the backbone of our safety solutions. By designing systems that actively manage risks, we help clients ensure that their operations continue smoothly and safely, even in challenging conditions.
When engineering controls aren’t enough, administrative controls seek to manage the way people work. These measures are focused on policies, procedures, and training that reduce the likelihood of human error or exposure to hazards. However, they’re not foolproof. Administrative controls rely on human compliance, and people are inherently unpredictable – fatigue, distractions, and lack of understanding can all lead to mistakes. That’s why administrative measures rank below elimination, substitution, and engineering controls in the hierarchy.
Examples of administrative controls include safety protocols, job rotation to reduce exposure to harmful conditions, regular safety drills, and signage that clearly marks danger zones. For instance, in the renewables sector, where workers might be exposed to electrical hazards during maintenance of wind turbines, administrative controls might involve detailed lockout/tagout procedures to ensure that equipment is properly de-energised before work begins.
At Flare, we recognise that while administrative controls are important, they can’t stand alone. In high-risk industries, it’s critical to back these up with solid engineering and technological solutions. For example, we work with clients to develop safety plans that incorporate both administrative measures and cutting-edge safety technology, such as real-time monitoring systems that provide early warnings of potential hazards.
By combining human-centred strategies with technological innovation, administrative controls can be significantly more effective. Our approach is to integrate these measures into the broader safety system, ensuring they complement physical and engineered controls for maximum protection.
At the base of the hierarchy, we find personal protective equipment (PPE). While PPE is essential in many work environments – especially in hazardous sectors like offshore oil and gas or marine – it's important to remember that PPE is the last resort. It should only be relied on when all other measures have been exhausted or when additional protection is needed to address residual risks that cannot be controlled through elimination, substitution, or engineering.
PPE includes items like hard hats, respirators, gloves, and fire-retardant clothing. In our hazardous environment services, we often provide advanced PPE solutions, including state-of-the-art breathing apparatus and gas detection devices that offer vital protection in high-risk environments. These tools are essential for safeguarding workers in situations where they might be exposed to toxic chemicals, gases, or other immediate dangers to life and health.
However, PPE is only effective if it’s used properly and consistently. One of the biggest challenges in safety management is ensuring that workers are trained not just in the use of PPE but also in understanding when it’s needed and how to wear it correctly. Improper use of PPE can give a false sense of security and lead to serious incidents if workers believe they are fully protected when, in fact, they are not.
Flare helps mitigate this risk by offering comprehensive training to ensure personnel are fully prepared to use PPE correctly. Our goal is to provide not only the equipment but also the knowledge needed to use it effectively. In high-risk environments, this training can make the difference between a near miss and a serious injury.
The hierarchy of controls offers a clear path for managing risks, but it’s more than just a theoretical model – it’s a practical tool that should inform every safety decision. From eliminating hazards at the source to providing the right protective equipment, the hierarchy prioritises solutions that make a real difference in high-risk sectors. It’s a strategy that aligns perfectly with Flare’s mission of delivering innovative, sustainable safety solutions across the industries we serve.
At Flare, we work with our clients to apply this hierarchy in a way that’s tailored to their unique operations. Whether we’re designing a fire protection system for an offshore platform or providing cutting-edge PPE for workers in hazardous environments, our approach is always grounded in the same principles: protecting lives by controlling risks as effectively as possible.
Ready to transform your safety standards? Get in touch with our team today to explore how we can help you implement smarter, more sustainable safety measures tailored to your specific needs.
