Hazard Identification and Risk Assessment (HIRA): Complete Guide for Workplace Safety

Introduction

Hazard Identification and Risk Assessment (HIRA) is one of the most important processes used to identify workplace hazards, understand the risks associated with those hazards and establish suitable controls to prevent accidents and occupational injuries.

Every workplace has hazards.

These hazards may come from:

Machinery.
Chemicals.
Electricity.
Fire.
Manual handling.
Material movement.
Working at height.
Slips and trips.
Poor housekeeping.
Vehicle movement.
Noise.
Heat.
Ergonomic conditions.
Emergency situations.

The purpose of HIRA is not simply to prepare a document.

The purpose of HIRA is to identify hazards before they cause harm and ensure that appropriate controls are implemented.

A good HIRA should reflect the actual workplace, not just generic safety information.

What is HIRA?

HIRA stands for:

H – Hazard

I – Identification

R – Risk

A – Assessment

It is a systematic process used to:

Identify hazards.
Identify who may be exposed.
Understand possible consequences.
Assess the level of risk.
Decide suitable control measures.
Implement controls.
Monitor the effectiveness of controls.
Review and update the assessment.

What is a Hazard?

A hazard is a source, situation or activity that has the potential to cause injury, ill health, damage or other harm.

Examples

Chemical

→ Chemical leakage.

Physical

→ Slippery floor.

Mechanical

→ Moving machinery.

Electrical

→ Damaged electrical cable.

Ergonomic

→ Repetitive manual handling.

Fire

→ Combustible material near an ignition source.

Vehicle

→ Forklift movement.

Environmental

→ Chemical spill.

What is Risk?

Risk is related to the possibility that a hazard will cause harm and the seriousness of the consequence.

In simple terms:

Risk = How likely the harm is × How serious the harm could be

For example:

Hazard

Chemical container leakage.

Possible Consequence

Chemical exposure or environmental contamination.

Risk

The risk depends on factors such as:

Type of chemical.
Quantity.
Exposure possibility.
Storage conditions.
Existing controls.
Likelihood of leakage.

Hazard vs Risk

These two terms are often confused.

Hazard

What can cause harm?

Example:

Chemical

Risk

What could happen and how serious/likely is it?

Example:

Chemical exposure causing skin or eye injury.

Another example:

Hazard: Wet floor.

Risk: Employee may slip and suffer an injury.

Why is HIRA Important?

HIRA helps organizations identify risks before accidents occur.

It can help to:

Prevent injuries.
Prevent occupational illness.
Improve workplace safety.
Prioritize safety controls.
Identify high-risk activities.
Improve employee awareness.
Support safe work procedures.
Identify PPE requirements.
Support emergency preparedness.
Support ISO 45001 requirements.
Encourage continual improvement.

When Should HIRA Be Conducted?

HIRA should not be treated as a one-time activity.

It should be conducted or reviewed when:

A new activity starts.
A new machine is introduced.
A new chemical is introduced.
The workplace changes.
Layout changes.
Work methods change.
An accident occurs.
A near miss occurs.
New legal requirements apply.
New equipment is introduced.
Existing controls are found ineffective.
Employees identify a new hazard.
Periodic review is due.

Change in activity should trigger a review of the related risk assessment.

Who Should Participate in HIRA?

HIRA should ideally involve people who understand the actual work.

Participants may include:

EHS/Safety representative.
Department supervisor.
Employees performing the activity.
Maintenance representative.
Warehouse representative.
Management representative.
Other competent persons where required.

Employee participation is especially valuable because workers often know the practical difficulties and hazards associated with the job.

HIRA Process – Step by Step

A practical HIRA process is:

Select Activity

↓

Identify Hazard

↓

Identify Who May Be Harmed

↓

Identify Possible Consequence

↓

Identify Existing Controls

↓

Assess Severity

↓

Assess Likelihood

↓

Calculate Risk Score

↓

Decide Additional Controls

↓

Assign Responsibility

↓

Implement Action

↓

Verify Effectiveness

↓

Review HIRA

Step 1 – Identify the Activity

First identify the activity being assessed.

Examples:

Loading.
Unloading.
Chemical storage.
Material movement.
Packing.
Manual handling.
Container unloading.
Waste handling.
Cleaning.
Fire emergency.
Maintenance.

A good HIRA should assess actual activities rather than writing only broad categories.

Step 2 – Identify the Hazard

Ask:

What can go wrong during this activity?

For example:

Activity

Manual handling of chemical bags.

Possible Hazards

Heavy load.
Awkward posture.
Repetitive lifting.
Dropping material.
Chemical package damage.

Step 3 – Identify Who May Be Harmed

Consider all people who may be affected.

They may include:

Employees.
Contract workers.
Drivers.
Visitors.
Maintenance personnel.
Security personnel.
Emergency responders.

Example

During container unloading, people who may be exposed include:

Warehouse employees.
Contract forklift operators.
Drivers.
Supervisors.

Step 4 – Identify Possible Consequences

Ask:

If the hazard occurs, what could happen?

Possible consequences include:

Minor injury.
Serious injury.
Fracture.
Chemical burn.
Eye injury.
Respiratory exposure.
Fire.
Property damage.
Environmental contamination.
Fatality.

The consequence should be realistic and related to the actual hazard.

Step 5 – Identify Existing Controls

Before deciding additional controls, identify what is already in place.

Examples:

SOP.
Training.
PPE.
Machine guarding.
Warning signage.
Fire extinguisher.
Spill kit.
Safety shower/eyewash.
Emergency procedure.
Preventive maintenance.
Safe stacking.
Inspection.
Supervision.

Do not assume that a control is effective simply because it exists on paper.

Step 6 – Assess Severity

Severity describes how serious the consequence could be.

A simple example is:

Severity	Description
1	Minor injury / negligible impact
2	First-aid level injury
3	Medical treatment / moderate injury
4	Serious injury / major impact
5	Fatality / very serious consequence

The exact scoring system should be defined in the organization's approved risk-assessment procedure.

Step 7 – Assess Likelihood

Likelihood describes how likely the event is to occur.

Example:

Likelihood	Description
1	Rare
2	Unlikely
3	Possible
4	Likely
5	Almost certain

Again, the organization should use its approved risk matrix and definitions.

Step 8 – Calculate Risk Score

A commonly used approach is:

Risk Score = Severity × Likelihood

For example:

Severity = 4

Likelihood = 3

Risk Score = 4 × 3 = 12

The organization's risk matrix should determine whether the resulting score is:

Low.
Medium.
High.
Critical.

Do not use a risk rating without defining what action is required for each category.

Example Risk Matrix

A simple example is:

Risk Score	Level	General Action
1–4	Low	Maintain controls and monitor
5–9	Medium	Improve controls where required
10–16	High	Priority action required
17–25	Critical	Immediate action / stop activity as appropriate

Important: This is only an example. The actual scoring ranges should match the organization's approved HIRA methodology.

Example HIRA – Manual Material Handling

Activity

Manual lifting of chemical bags.

Hazard

Heavy/awkward load.

Possible Consequence

Back strain or musculoskeletal injury.

Existing Controls

Training.
Safety shoes.
Manual-handling procedure.
Team lifting where required.

Additional Controls

Suitable trolley.
Reduce manual lifting where possible.
Improve storage height.
Use mechanical assistance where feasible.
Refresher training.

Risk

Assess according to the organization's approved severity and likelihood criteria.

Example HIRA – Chemical Storage

Activity

Storage of packed chemicals.

Hazard

Damaged/leaking chemical container.

Possible Consequence

Chemical exposure.
Skin/eye injury.
Spill.
Environmental contamination.
Fire risk depending on chemical properties.

Existing Controls

Proper storage.
Labeling.
SDS.
Inspection.
PPE.
Spill kit.
Emergency procedure.

Additional Controls

Regular package inspection.
Improved stacking.
Damaged-package isolation.
Employee awareness.
Review of storage compatibility where applicable.

Example HIRA – Forklift Movement

Activity

Forklift movement during loading/unloading.

Hazard

Collision with pedestrian or material.

Possible Consequence

Serious injury.
Fatality.
Material damage.
Property damage.

Existing Controls

Trained operator.
Designated movement area.
Warning signs.
Safety shoes.
High-visibility clothing where required.
Spotter/banksman where required.

Additional Controls

Separate pedestrian route.
Traffic management.
Speed control.
Visibility improvement.
Regular inspection.

Example HIRA – Chemical Spill

Activity

Handling/storage of chemical packages.

Hazard

Chemical spill due to damaged package.

Possible Consequence

Chemical exposure.
Slip hazard.
Fire risk depending on chemical.
Environmental contamination.

Existing Controls

Spill kit.
PPE.
Chemical handling procedure.
SDS.
Employee training.
Emergency response procedure.

Additional Controls

Improve packaging inspection.
Review stacking.
Conduct spill-response drill.
Investigate recurring package damage.

Example HIRA – Slips and Trips

Activity

Walking inside warehouse.

Hazard

Wet floor, uneven surface or obstruction.

Possible Consequence

Slip, trip and fall injury.

Existing Controls

Housekeeping.
Inspection.
Warning signs.
Clear walkways.

Additional Controls

Immediate cleaning.
Repair damaged flooring.
Improve storage arrangement.
Mark pedestrian routes.

Example HIRA – Fire Emergency

Activity

Workplace operation.

Hazard

Fire due to ignition source, electrical fault or other applicable source.

Possible Consequence

Burns.
Smoke exposure.
Property damage.
Serious injury.
Fatality.

Existing Controls

Fire extinguishers.
Fire alarm/siren.
Emergency exits.
Evacuation layout.
Fire Marshals.
Assembly point.
Emergency contacts.
Mock drills.

Additional Controls

Regular inspection.
Fire training.
Emergency drill review.
Correct deficiencies identified during drills.

Hierarchy of Controls

One of the most important concepts in risk control is the Hierarchy of Controls.

Controls should generally be considered in this order:

1. Elimination

Remove the hazard completely.

Example

Remove an unnecessary hazardous activity.

2. Substitution

Replace the hazard with something less hazardous.

Example

Use a less hazardous chemical where technically and operationally suitable.

3. Engineering Controls

Separate people from the hazard.

Examples:

Machine guards.
Barriers.
Ventilation.
Interlocks.
Guardrails.
Mechanical handling equipment.

4. Administrative Controls

Change the way work is performed.

Examples:

SOP.
Training.
Work instructions.
Job rotation.
Warning signs.
Inspection.
Permit systems where applicable.

5. PPE

Protect the worker with personal protective equipment.

Examples:

Safety shoes.
Gloves.
Safety goggles.
Face shield.
Respiratory protection where required.
Protective clothing.

PPE is important, but it should not automatically be considered the first or only control.

Example of Hierarchy of Controls

Hazard

Manual lifting of heavy bags.

Elimination

Avoid unnecessary manual lifting.

Substitution

Use smaller/lighter packages where feasible.

Engineering

Use pallet trolley or mechanical handling equipment.

Administrative

Manual-handling training and safe-work procedure.

PPE

Safety shoes and other task-specific PPE.

This layered approach is stronger than simply giving employees gloves or safety shoes.

Normal, Abnormal and Emergency Conditions

HIRA should consider different operating conditions.

Normal

Routine activity.

Example:

Normal chemical storage.

Abnormal

Non-routine or unusual condition.

Example:

Damaged pallet or unusual material-handling situation.

Emergency

Situation requiring immediate response.

Example:

Major chemical spill or fire.

This classification can help ensure that non-routine and emergency situations are not overlooked.

Example Classification

Activity	Situation	Classification
Chemical storage	Normal storage	Normal
Damaged package	Package leakage	Abnormal
Chemical spill	Major uncontrolled spill	Emergency
Material unloading	Routine unloading	Normal
Forklift breakdown	Equipment failure	Abnormal
Fire	Fire emergency	Emergency

HIRA for a Chemical Warehouse

A chemical warehouse may consider hazards related to:

Chemical storage.
Chemical leakage.
Manual handling.
Material stacking.
Pallet condition.
Forklift movement.
Hand pallet trolley.
Loading/unloading.
Container unloading.
Fire.
Electrical systems.
Slips and trips.
Heat stress.
Poor housekeeping.
Emergency evacuation.
Damaged material.
Expired material.
Waste handling.

The assessment should be based on the warehouse's actual activities.

HIRA and Environmental Risks

Some hazards can affect both people and the environment.

Example

Hazard: Chemical leakage.

Safety Consequence:

Employee chemical exposure.

Environmental Consequence:

Potential contamination.

Therefore, safety and environmental assessments can be connected where appropriate, while maintaining their specific objectives.

HIRA and PPE Selection

HIRA should help determine PPE requirements.

For example:

Hazard

Chemical splash.

Possible Exposure

Eyes and skin.

Possible PPE

Chemical-resistant gloves.
Safety goggles.
Face shield where required.
Suitable protective clothing.

PPE should be selected based on:

Chemical properties.
Exposure route.
Task.
Duration.
Concentration.
Manufacturer/SDS information.
Applicable requirements.

HIRA and SOP

HIRA and SOPs should support each other.

HIRA

Identifies:

What can go wrong?

SOP

Explains:

How should the activity be performed safely?

For example:

HIRA identifies chemical spill risk.

↓

SOP defines safe chemical handling.

↓

Employee follows SOP.

↓

Inspection verifies implementation.

↓

Incident/near miss leads to review.

This creates a continuous safety system.

HIRA Review After an Incident

If an accident or near miss occurs, the related HIRA should be reviewed.

Ask:

Was the hazard identified?
Was the risk assessment realistic?
We're existing controls actually implemented?
Were controls effective?
Did the work method change?
Was there an unexpected hazard?
Is additional control required?

The HIRA should be updated where necessary.

HIRA Review After a Near Miss

Near misses are especially useful for HIRA improvement.

Example

A pallet almost falls during material movement.

The committee should ask:

Was stacking height appropriate?

Was the pallet damaged?

Was the load stable?

Was the trolley/forklift operated correctly?

Was the storage arrangement suitable?

If the existing HIRA did not adequately address the hazard, it should be reviewed.

HIRA Action Plan

A good HIRA should identify actions when existing controls are not sufficient.

Hazard	Risk	Additional Control	Responsible	Target Date	Status
Manual handling	Back injury	Provide suitable trolley	Warehouse		Open
Chemical leakage	Chemical exposure	Improve package inspection	EHS		Open
Forklift movement	Collision	Improve traffic segregation	Warehouse		Open
Slips/trips	Fall injury	Repair floor	Maintenance		Closed

HIRA Effectiveness Verification

Completing an action does not automatically mean the risk is controlled.

Example

Action: Safety signage installed.

Verification should ask:

Is the sign visible?
Is it in the correct location?
Do employees understand it?
Has unsafe behavior reduced?

Similarly:

Action: Training completed.

Verification:

Are employees following the safe procedure?
Has the hazard reduced?
Are observations showing improvement?

Safety Committee and HIRA

The Safety Committee can support HIRA by:

Reviewing new hazards.
Discussing employee concerns.
Reviewing near misses.
Reviewing inspection findings.
Suggesting controls.
Tracking HIRA actions.
Reviewing repeated hazards.

Employee participation makes HIRA more practical.

Common HIRA Mistakes

1. Copying Generic Hazards

A HIRA should reflect the actual workplace.

2. Identifying Only Obvious Hazards

Consider normal, abnormal and emergency situations.

3. Ignoring Employees

Workers often know practical hazards that are missed during desk-based assessments.

4. Listing PPE as the Only Control

Use the hierarchy of controls.

5. Not Considering Consequences Properly

Different hazards can have very different consequences.

6. Incorrect Risk Scoring

Severity and likelihood should follow the approved risk matrix.

7. No Action Plan

High risks should lead to appropriate control actions.

8. No Responsible Person

Actions need ownership.

9. No Review

HIRA should be reviewed after changes, incidents, near misses and when required by the organization's system.

10. Treating HIRA as an Audit Document Only

The real purpose is risk reduction.

HIRA Checklist

Use the following checklist to review whether a HIRA is practical:

☐ All major workplace activities are identified.

☐ Normal activities are covered.

☐ Abnormal conditions are considered.

☐ Emergency situations are considered.

☐ Hazards are clearly identified.

☐ Potential consequences are identified.

☐ People exposed to the hazard are identified.

☐ Existing controls are documented.

☐ Severity criteria are defined.

☐ Likelihood criteria are defined.

☐ Risk score is calculated correctly.

☐ Risk level is identified.

☐ Additional controls are identified where necessary.

☐ Hierarchy of controls is considered.

☐ Responsible persons are assigned.

☐ Target dates are defined.

☐ Actions are tracked.

☐ Effectiveness is verified.

☐ HIRA is reviewed after changes.

☐ Employees participate where appropriate.

Sample HIRA Format

A practical HIRA table can contain:

Sr. No.	Situation	Activity	Hazard	Risk / Consequence	Existing Controls	Severity	Likelihood	Risk Score	Action Plan	Responsible Person	Status
1	Normal	Chemical storage	Damaged package	Chemical exposure	Inspection, PPE, SDS	4	2	8	Improve package inspection	EHS	Open
2	Normal	Material movement	Manual handling	Musculoskeletal injury	Training, trolley	3	3	9	Review handling method	Warehouse	Open
3	Normal	Forklift movement	Pedestrian collision	serious injury	Trained operator, signage	5	2	10	Improve segregation	Warehouse	Open
4	Abnormal	Damaged pallet	Falling material	Injury/material damage	Inspection	4	2	8	Replace damaged pallet	Warehouse	Closed
5	Emergency	Chemical spill	Chemical release	Exposure/environmental impact	Spill kit, ERP	5	2	10	Conduct spill drill	EHS	Open

Note: The scores above are illustrative examples only. Actual severity, likelihood and risk levels must be determined using the organization's approved risk-assessment criteria.

HIRA – Practical Warehouse Example

Consider a warehouse where packed chemical bags are moved using a hand pallet trolley.

Activity

Moving chemical bags.

Hazard

Uncontrolled trolley movement.

Possible Consequences

Employee injury.
Collision.
Material damage.
Chemical package damage.

Existing Controls

Trained employees.
Suitable trolley.
Clear passage.
Safety shoes.
Workplace inspection.

Additional Control

Inspect trolley wheels and maintain clear pedestrian routes.

Verification

During the next workplace inspection, verify:

Trolley condition.
Passage condition.
Employee working method.
Any new observations or near misses.

This is how HIRA should connect with actual workplace operations.

HIRA and ISO 45001

HIRA supports the risk-based approach of an ISO 45001 Occupational Health and Safety Management System.

It can support:

Hazard identification.
OH&S risk assessment.
Determination of controls.
Worker participation.
Operational planning.
Emergency preparedness.
Incident learning.
Corrective action.
Continual improvement.

However:

Having a HIRA document does not automatically mean that all ISO 45001 requirements are fulfilled.

The controls identified through HIRA should be implemented and maintained in actual workplace operations.

HIRA Improvement Cycle

A practical improvement cycle is:

Identify Hazard

↓

Assess Risk

↓

Control Risk

↓

Implement

↓

Monitor

↓

Learn from Incidents/Near Misses

↓

Review HIRA

↓

Improve Controls

This makes HIRA a living safety process rather than a static document.

Personal Experience

From my experience in warehouse operations and ISO management systems, I believe HIRA is most useful when it is prepared by actually observing the work. In a chemical warehouse, hazards can change depending on activities such as loading, unloading, stacking, manual material movement, damaged packages and emergency situations. Employees often provide useful information about practical risks that may not be visible from a desk-based assessment. I have found that a good HIRA should not only identify hazards but should also clearly show the existing controls, additional actions, responsible person and status. Most importantly, the controls identified in HIRA should be visible in actual workplace practice.

Key Learning

HIRA should be based on actual workplace activities.
Hazard and risk are different concepts.
Employees should participate where appropriate.
Normal, abnormal and emergency conditions should be considered.
Risk should be assessed using an approved methodology.
High-risk activities require appropriate controls.
Hierarchy of controls should be considered.
PPE should not be the only control.
Near misses can improve HIRA.
Incidents should trigger review of relevant risk assessments.
Corrective actions need ownership and target dates.
Effectiveness should be verified.
HIRA should be periodically reviewed.
HIRA should support actual risk reduction, not just audit documentation.

Frequently Asked Questions (FAQ)

Q1. What is HIRA?

HIRA stands for Hazard Identification and Risk Assessment. It is a systematic process for identifying workplace hazards, assessing associated risks and determining suitable controls.

Q2. What is the difference between hazard and risk?

A hazard is something that can cause harm. Risk relates to the likelihood and severity of harm resulting from that hazard.

Q3. Why is HIRA important?

HIRA helps identify hazards before they cause accidents and helps organizations prioritize appropriate control measures.

Q4. Who should participate in HIRA?

Safety/EHS personnel, supervisors, workers performing the activity and other relevant competent persons should participate as appropriate.

Q5. When should HIRA be reviewed?

It should be reviewed when there are changes in activities, equipment, chemicals, layout or work methods, and after relevant incidents, near misses or other triggers defined by the organization's procedure.

Q6. What is the hierarchy of controls?

The hierarchy generally consists of:

Elimination → Substitution → Engineering Controls → Administrative Controls → PPE

Q7. Is PPE enough to control a hazard?

Usually, PPE should not be considered the only control when higher-level controls are reasonably practicable.

Q8. Can HIRA cover chemical hazards?

Yes. Chemical storage, handling, leakage, exposure, spills and emergency situations can be included.

Q9. Can HIRA cover fire risk?

Yes. Fire hazards and emergency conditions can be included in the risk assessment.

Q10. Should near misses be considered in HIRA?

Yes. Near misses can provide valuable information about hazards and weaknesses in existing controls.

Q11. Does HIRA support ISO 45001?

Yes. HIRA supports hazard identification, OH&S risk assessment and determination of controls within an ISO 45001 management system.

Q12. Is HIRA a one-time exercise?

No. HIRA should be maintained and reviewed when required by changes, incidents, new hazards, ineffective controls and the organization's review process.

Q13. What should a HIRA action plan contain?

It should normally identify the required action, responsible person, target date and status. The organization may also track priority and effectiveness.

Q14. What is a risk score?

A risk score is a numerical value used by an organization to classify risk based on its defined severity and likelihood criteria.

Q15. Why should employees participate in HIRA?

Employees understand the actual work and can identify practical hazards, unsafe conditions and difficulties that may not be obvious to others.

Conclusion

Hazard Identification and Risk Assessment (HIRA) is one of the foundations of an effective workplace safety system.

The basic approach is:

Identify

↓

Assess

↓

Control

↓

Monitor

↓

Review

↓

Improve

A good HIRA should answer five important questions:

What activity are we performing?
What can cause harm?
Who can be affected?
How serious and likely is the risk?
What controls are required to prevent the harm?

For warehouses and chemical workplaces, HIRA should consider practical activities such as:

Chemical storage.
Loading and unloading.
Manual material handling.
Material movement.
Safe stacking.
Forklift movement.
Damaged packages.
Fire.
Chemical spills.
Housekeeping.
Electrical hazards.
Heat stress.
Emergency situations.

The most important principle is:

Do not wait for an accident to identify a hazard. Identify the hazard, assess the risk and control it before harm occurs.

HIRA becomes truly effective when the controls identified in the assessment are implemented in the workplace, employees understand them, inspections verify them and the assessment is updated when conditions change.

Hazard identification + risk assessment + effective controls + employee participation + continual improvement = safer workplace.

Discussion

Does your workplace review HIRA after a near miss or change in activity? Which hazard is the most difficult to control in your workplace—chemical, manual handling, fire, forklift, electrical or something else? Share your experience in the comments.

About the Author

Written by Mahesh Chand

Warehouse Safety Professional | Chemical Warehousing | Fire Safety | ISO 9001 & ISO 45001

Mahesh Chand has 12+ years of professional experience in chemical warehousing, industrial safety, warehouse operations, fire prevention, HIRA, risk assessment, emergency preparedness and ISO management systems. Through Trading Hatke, he shares practical workplace safety, environmental awareness and ISO knowledge in simple and easy-to-understand language.

📌 Follow Trading Hatke for more practical safety guides, warehouse management tips, environmental awareness and ISO best practices.

Disclaimer: This article is intended for general educational and informational purposes. HIRA methodology, risk criteria and control requirements should be established according to applicable laws, standards, organizational procedures and competent professional advice.

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Wednesday, June 24, 2026