Hazard Recognition and Control Training Service | in Dammam - Riyadh - Jeddah - Makkah

1. Introduction to Hazard Recognition and Control

• Hazard versus risk definition including (hazard as potential harm, risk as probability and severity, exposure as key factor)

• Importance of hazard recognition including (injury prevention, regulatory compliance, cost reduction, productivity improvement, liability protection)

• OSHA General Duty Clause per 29 CFR 1910 including (employer responsibility for hazard-free workplace, recognized hazards, industry standards, feasible controls)

• Incident causation models including (domino theory Heinrich, loss causation Bird, Swiss cheese Reason, multiple causation, prevention focus)

• Proactive versus reactive approach including (hazard identification before incidents, prevention culture, continuous improvement, anticipation)

• Personal responsibility including (worker rights and responsibilities, hazard reporting, stop work authority, participation in safety)

• Course objectives and outcomes including (hazard identification skills, risk assessment, control selection, practical application, workplace improvement)

2. Types of Workplace Hazards

2.1 Safety Hazards (Physical Hazards)

• Mechanical hazards including (moving parts, pinch points, rotating equipment, crushing, shearing, entanglement per OSHA 1910.212)

• Electrical hazards per OSHA 1910 Subpart S including (shock, arc flash, fire, burns, contact with energized parts, improper grounding)

• Fall hazards per OSHA 1910.23 and 1926 Subpart M including (falls from elevation, same level falls, ladder hazards, scaffolding, unprotected edges)

• Struck-by and caught-between hazards including (falling objects, flying particles, moving vehicles, equipment, compressed materials)

• Fire and explosion hazards per NFPA including (flammable materials, ignition sources, confined spaces, combustible dust, hot work)

2.2 Health Hazards (Chemical, Biological, Physical Agents)

• Chemical hazards per OSHA 1910.1200 Hazcom including (toxic substances, corrosives, irritants, carcinogens, sensitizers, routes of exposure)

• Biological hazards including (bacteria, viruses, fungi, bloodborne pathogens per OSHA 1910.1030, mold, animal-borne diseases)

• Physical agents including (noise per OSHA 1910.95, vibration, radiation ionizing and non-ionizing, extreme temperatures, pressure)

• Air contaminants per OSHA PELs including (dusts, fumes, mists, gases, vapors, permissible exposure limits, monitoring requirements)

• Chronic versus acute exposure including (long-term low-level, short-term high-level, cumulative effects, latency periods)

2.3 Ergonomic and Psychosocial Hazards

• Ergonomic hazards including (repetitive motion, forceful exertion, awkward postures, contact stress, vibration, musculoskeletal disorders)

• Manual material handling per NIOSH Lifting Equation including (lifting, carrying, pushing, pulling, back injuries, proper techniques)

• Workstation design including (computer ergonomics, standing workstations, tool design, work height, reach zones)

• Psychosocial hazards including (workplace stress, violence, bullying, harassment, fatigue, workload, work-life balance)

3. Hazard Identification Methods and Techniques

3.1 Workplace Inspections

• Planned inspection purpose including (proactive hazard identification, compliance verification, trend analysis, continuous improvement)

• Inspection types including (comprehensive facility, area-specific, equipment-focused, pre-use, post-incident, seasonal)

• Inspection preparation including (checklists, previous reports, regulatory standards, PPE, tools, scheduling, notification)

• Systematic inspection approach including (methodical coverage, all areas and shifts, different conditions, employee input, documentation)

• Observation techniques including (looking beyond obvious, questioning normal, near-miss attention, housekeeping, maintenance)

3.2 Job Hazard Analysis (JHA) and Job Safety Analysis (JSA)

• JHA/JSA purpose per OSHA including (task-level hazard identification, control development, training basis, procedure improvement)

• Task selection criteria including (injury history, severity potential, new tasks, infrequent tasks, changed processes)

• JHA process steps including (task breakdown, hazard identification per step, risk assessment, control measures, procedure documentation)

• Task breakdown including (observable actions, logical sequence, manageable steps typically 5-10, avoid too broad or detailed)

• Hazard identification per step including (what could go wrong, energy sources, environmental factors, human error potential)

3.3 Hazard Reporting Systems

• Employee hazard reporting including (reporting mechanisms, non-punitive culture, feedback loops, timely response, recognition)

• Near-miss reporting including (definition, precursor to incidents, learning opportunity, investigation, corrective action)

• Reporting barriers including (fear of blame, perceived futility, time constraints, lack of awareness, overcoming barriers)

• Reporting incentives including (positive reinforcement, recognition programs, safety leadership, transparency, visible action)

4. Risk Assessment and Evaluation

4.1 Likelihood and Severity Determination

• Likelihood assessment including (frequency categories rare to almost certain, probability, historical data, expert judgment, scenario analysis)

• Severity assessment including (consequence categories catastrophic to negligible, injury severity, property damage, business interruption)

• Exposure factors including (number of people, duration, frequency, proximity to hazard, vulnerable populations)

• Risk estimation including (qualitative descriptive, semi-quantitative scoring, quantitative numerical probability)

4.2 Risk Matrix Application

• Risk matrix structure including (likelihood axis, severity axis, risk levels high/medium/low, color coding red/yellow/green)

• Risk level interpretation including (high risk immediate action, medium risk planned action, low risk acceptable with monitoring)

• Risk ranking including (prioritization, resource allocation, risk tolerance, management decision, documented rationale)

• Limitations of risk matrices including (subjectivity, scale compression, false precision, understanding context)

4.3 Risk Acceptance Criteria

• Risk tolerance levels including (unacceptable, ALARP as low as reasonably practicable, acceptable, cost-benefit)

• Regulatory requirements including (OSHA standards as minimum, industry best practices, corporate policies, stakeholder expectations)

• Decision-making authority including (operational decisions, management approval, risk acceptance documentation)

• Residual risk including (risk remaining after controls, ongoing monitoring, continuous improvement, communication)

5. Hierarchy of Controls Framework

5.1 Hierarchy of Controls Overview

• Hierarchy of Controls per NIOSH including (elimination, substitution, engineering controls, administrative controls, PPE, effectiveness order)

• Effectiveness ranking including (most effective elimination, least effective PPE, reliability considerations, human factors)

• Selection principles including (highest feasible level, multiple controls layers, defense in depth, Swiss cheese model)

• Control failure considerations including (PPE depends on use, administrative requires compliance, engineering more reliable, elimination most reliable)

5.2 Elimination and Substitution

• Elimination including (removing hazard entirely, process redesign, automation, different approach, most effective permanent solution)

• Elimination examples including (remote operation, mechanization, eliminate confined space entry, redesign to avoid heights, hazardous material removal)

• Substitution including (replacing with less hazardous, different material/process/equipment, reduced risk, feasibility assessment)

• Substitution examples including (non-toxic for toxic chemicals, lower voltage, smaller quantities, water-based for solvent-based, quieter equipment)

5.3 Engineering Controls

• Engineering controls definition including (physical changes, built-in protection, does not rely on behavior, passive safeguarding)

• Machine guarding per OSHA 1910.212 including (point of operation guards, barrier guards, interlocks, two-hand controls, light curtains)

• Ventilation systems including (local exhaust, dilution ventilation, fume hoods, capture velocity, air changes, negative pressure)

• Enclosure and isolation including (separate hazardous processes, barriers, distance, enclosed equipment, soundproof rooms)

• Engineering control examples including (fall protection railings, exhaust systems, machine guards, ergonomic workstation design, noise enclosures)

5.4 Administrative Controls

• Administrative controls definition including (work practices, procedures, training, policies, behavior-dependent, requires enforcement)

• Safe work procedures including (written procedures, task-specific, clear steps, accessible, training, regular review)

• Work permits including (hot work, confined space, excavation, lockout/tagout, energy isolation, authorization)

• Training and competency including (initial training, refresher, competency verification, on-the-job training, supervision)

• Administrative examples including (job rotation, work-rest schedules, reduced exposure time, signage, access restrictions, buddy system)

5.5 Personal Protective Equipment (PPE)

• PPE as last resort per OSHA 1910.132 including (least effective, depends on proper use, maintenance, training, supplement not substitute)

• PPE hazard assessment per OSHA 1910.132(d) including (workplace evaluation, hazard identification, appropriate PPE selection, certification)

• PPE types including (head, eye/face, hearing, respiratory, hand, foot, body, fall protection, selection criteria)

• PPE program elements including (hazard assessment, selection, training, use, maintenance, inspection, replacement)

• Respiratory protection per OSHA 1910.134 including (fit testing, medical evaluation, written program, APR versus SCBA, atmosphere testing)

6. Specific Hazard Recognition and Control

6.1 Fall Protection and Working at Heights

• Fall hazards identification per OSHA 1910.23/1926 Subpart M including (unprotected edges 4 feet general industry/6 feet construction, openings, holes, skylights)

• Fall protection systems including (guardrails, safety nets, personal fall arrest systems, warning lines, covers)

• Ladder safety including (inspection, setup angle 75 degrees, three-point contact, extension above landing, securing)

• Scaffolding safety including (competent person, platforms, guardrails, access, load capacity, inspection)

• Fall protection plan including (hazard identification, system selection, rescue plan, training, equipment inspection)

6.2 Electrical Safety

• Electrical hazard recognition per NFPA 70E including (shock, arc flash, contact voltage, wet conditions, improper grounding)

• Lockout/Tagout per OSHA 1910.147 including (energy isolation, authorized employees, procedures, locks and tags, verification)

• Electrical safe work practices including (de-energization, testing before touch, qualified persons, PPE, arc flash boundaries)

• Ground Fault Circuit Interrupter (GFCI) per OSHA 1926.404 including (construction sites, wet locations, 6 mA trip, testing)

• Electrical controls including (insulation, guarding, grounding, barriers, labeling, spacing, working clearances per NEC 110.26)

6.3 Machine Safeguarding

• Machine hazard types including (point of operation, in-running nip points, rotating parts, flying chips, reciprocating parts)

• Guarding methods per OSHA 1910.212 including (fixed guards, interlocked guards, adjustable guards, self-adjusting)

• Safeguarding devices including (presence-sensing, pullback, restraint, two-hand control, gates)

• Lockout/Tagout for maintenance including (energy control procedure, authorized training, periodic inspection, group lockout)

• Machine safety controls including (emergency stops, guards in place, proper adjustment, no bypassing, maintenance)

6.4 Chemical Hazards and Hazard Communication

• Chemical hazard identification per OSHA 1910.1200 including (SDS review Section 2, GHS pictograms, hazard statements, health and physical hazards)

• Routes of exposure including (inhalation most common, skin absorption, ingestion, injection, prevention for each route)

• Chemical controls including (substitution, closed systems, ventilation, personal protective equipment, hygiene practices)

• Hazard communication program including (chemical inventory, SDS access, container labeling, training, written program)

• Spill response including (containment, cleanup, PPE, disposal, reporting, prevention)

6.5 Ergonomic Hazards

• Ergonomic risk factors including (repetition, force, awkward postures, static postures, contact stress, vibration, cold)

• Manual material handling controls including (NIOSH lifting equation, mechanical aids, team lifting, load reduction, workstation height)

• Workstation ergonomics including (adjustable furniture, monitor placement, keyboard position, neutral postures, footrests)

• Tool selection including (ergonomic handles, powered tools, right tool for job, reduced vibration, maintenance)

• Ergonomic program including (risk assessment, engineering controls, training, early reporting, medical management)

7. Control Implementation and Effectiveness Verification

7.1 Control Measure Selection and Design

• Selection criteria including (hazard elimination preference, feasibility, cost-effectiveness, reliability, acceptance, compatibility)

• Engineering design including (fail-safe design, redundancy, maintenance accessibility, interlocks, warning systems)

• Interim controls including (temporary measures during permanent implementation, timeline, monitoring, risk communication)

• Employee involvement including (frontline input, solution development, acceptance, ownership, practical perspective)

7.2 Control Implementation

• Implementation planning including (timeline, responsibilities, resources, communication, training, monitoring)

• Procurement and installation including (specifications, qualified contractors, commissioning, testing, documentation)

• Training and communication including (affected employees, proper use, limitations, maintenance, reporting deficiencies)

• Change management including (procedure updates, signage, new equipment orientation, supervision, enforcement)

7.3 Verification and Monitoring

• Control effectiveness verification including (hazard reduction measurement, exposure assessment, incident reduction, employee feedback)

• Monitoring methods including (inspections, observations, environmental monitoring, exposure assessment, testing)

• Performance indicators including (leading indicators control function, lagging indicators incidents and injuries, trending)

• Continuous improvement including (control failures, better technology, lessons learned, optimization, feedback loop)

8. Safety Culture and Proactive Hazard Management

8.1 Safety Leadership and Culture

• Management commitment including (visible leadership, resource allocation, accountability, priority demonstration, communication)

• Employee engagement including (hazard reporting, participation in JHAs, safety committees, suggestion programs, ownership)

• Safety culture maturity including (reactive, dependent, independent, interdependent, generative levels)

• Just culture including (error tolerance, accountability for recklessness, learning from mistakes, non-punitive reporting)

8.2 Proactive Hazard Management Programs

• Behavior-based safety including (observation programs, peer feedback, positive reinforcement, barrier removal, data analysis)

• Safety committees including (worker-management collaboration, hazard identification, recommendation development, communication)

• Pre-task planning including (job briefings, hazard identification, control verification, communication, authorization)

• Continuous hazard identification including (ongoing awareness, change management, new equipment, process modifications)

8.3 Training and Competency

• Training needs assessment including (regulatory requirements, job-specific hazards, competency gaps, new employees, changes)

• Training methods including (classroom, hands-on, on-the-job, e-learning, toolbox talks, competency verification)

• Competency verification including (knowledge testing, performance observation, skill demonstration, certification)

• Refresher training including (periodic reinforcement, procedure updates, incident lessons, regulatory changes, annual typically)