If you’re responsible for safety, you’ve likely searched for the types of workplace hazards that matter most to your operations. This guide goes deeper than the usual list. You’ll get clear definitions, practical examples by category, and step-by-step controls—plus how digital tools like ToolKitX ePTW, LOTO (Lock Out Tag Out), and mobile checklists help you identify, assess, and mitigate risk at scale.
What is a workplace hazard?
A workplace hazard is anything with the potential to cause harm—injury, illness, property damage, or environmental impact. Hazards may be obvious (unguarded machinery) or hidden (manual-handling fatigue, solvent exposure, heat stress).
Hazard vs. Risk (simple distinction)
- Hazard: the source of potential harm (e.g., energized equipment).
- Risk: the chance that harm occurs and how severe it could be (likelihood × severity).
Why classification matters
Many teams treat safety as reactive—investigating incidents instead of preventing them.
That leaves blind spots that surface during audits, turnarounds, and high-risk tasks, costing time, fines, and trust.
Classifying hazards and applying a repeatable risk-control process (with digital enforcement) ensures nothing critical is missed and controls are actually used.
The 6 types of workplace hazards (with examples & controls)
1) Safety (mechanical) hazards
Examples: Slips/trips/falls, uneven surfaces, working at height, moving vehicles, pinch/crush points, hot work, confined spaces.
Controls:
- Engineering: machine guarding, non-slip surfaces, guardrails, interlocks.
- Administrative: safe work procedures, spotters, traffic segregation, permits.
- PPE: helmets, fall protection, eye/hand protection.
- Digital: ePTW for hot work/height/confined space; LOTO (Lock Out Tag Out) to verify isolation; pre-task checklists.
2) Chemical hazards
Examples: Solvents, acids/alkalis, welding fumes, flammable gases, cleaning agents, isocyanates, diesel exhaust.
Controls:
- Engineering: closed systems, local exhaust ventilation, gas detection.
- Administrative: SDS access, labeling, storage/compatibility rules, spill readiness.
- PPE: respirators, chemical-resistant gloves, goggles, aprons.
- Digital: inventory with SDS links, auto-prompts for ventilation/PPE, spill logs and CAPAs in your HSE module.
3) Biological hazards
Examples: Blood-borne pathogens, mold, Legionella, animal waste, plant materials, tick-borne diseases, pandemic exposure.
Controls:
- Engineering: isolation, filtration, safe waste handling.
- Administrative: hygiene protocols, vaccination policies, exposure monitoring, fit-for-work checks.
- PPE: gloves, masks/respirators, face shields, gowns.
- Digital: exposure registers, cleaning schedules, training proofs, incident/near-miss reporting.
4) Physical hazards
Examples: Noise, vibration, radiation (ionizing/non-ionizing), extreme temperatures, pressure systems, UV.
Controls:
- Engineering: enclosures, damping, shielding, insulation, automated handling.
- Administrative: rotation, monitored exposure limits, signage, routine inspections.
- PPE: hearing protection, insulated clothing, eye/face protection.
- Digital: monitoring records, calibration reminders, corrective-action workflows.
5) Ergonomic hazards
Examples: Repetitive motions, awkward postures, heavy lifts, poorly designed workstations, tool vibration, extended screen time.
Controls:
- Engineering: adjustable workstations, lift assists, tool redesign.
- Administrative: job rotation, micro-breaks, ergonomic assessments, manual-handling training.
- PPE: anti-vibration gloves, supports (as last resort).
- Digital: ergonomic assessment templates, action tracking, supervisor sign-off.
6) Psychosocial (workload) hazards
Examples: Excessive workload, time pressure, shift fatigue, violence/aggression, bullying/harassment, lone work.
Controls:
- Engineering/Tech: access controls, panic buttons, lone-worker check-ins, fall detection.
- Administrative: staffing norms, de-escalation training, reporting channels, EAP referrals.
- PPE: situational (body-worn cameras where lawful, alarms).
- Digital: lone-worker apps, incident reporting with escalation, privacy-aware case management.
7) Electrical hazards
What it is: Exposure to electricity that can cause shock, burns, arc flash/arc blast, fires, or explosions.
Examples:
- Live parts/exposed conductors, damaged cords, improper earthing/grounding
- Overloaded circuits and panels, defective insulation, wet locations
- Temporary power, portable tools, extension leads, makeshift connections
- Proximity to overhead/underground lines, testing/troubleshooting on energized gear
Controls:
- Engineering: De-energize where feasible; robust guarding/enclosures (correct IP ratings); GFCI/RCD protection; proper earthing/bonding; arc-resistant switchgear; interlocks; insulated barriers; correct cable management.
- Administrative: Electrical safe-work practices; energized-work permits only when justified; qualified persons only; up-to-date single-line diagrams; approach boundaries (limited/restricted); test-before-touch; tool/cord inspection routines; clear arc-flash labels and panel ID.
- PPE: Voltage-rated gloves and tools, arc-rated (AR) clothing (balaclava/hood, face shield), dielectric footwear, eye/face/hearing protection.
- Digital (ToolKitX): Electrical ePTW workflows, digital LOTO (Lock Out Tag Out) with isolation steps and photo verification, job briefing templates, training/competency records, and automated reminders for inspection/calibration.
How to identify hazards (and not miss the hidden ones)
- Walkthroughs & inspections: Use structured, task-based checklists—general + area-specific (labs, workshops, loading bays).
- Document reviews: SDS, change management, maintenance logs, incident/near-miss history, CAPAs.
- Worker input: Toolbox talks, stop-work authority, anonymous suggestions.
- Dynamic risk assessments (DRA): Quick on-the-spot checks when conditions change—weather, contractor activities, simultaneous operations (SIMOPS).
- Change & non-routine work: Treat hot work, tie-ins, and startups with elevated scrutiny and permit-to-work gates.
From hazards to a risk-control plan
Build a simple risk matrix
- Score likelihood (Rare → Frequent) and severity (Minor → Catastrophic).
- Compute Risk Rating to prioritize controls and approvals.
- Set acceptance criteria: what requires supervisor or HSE sign-off?
Apply the hierarchy of controls (Top → Bottom)
- Elimination: remove the hazard (e.g., pre-fabrication to avoid hot work).
- Substitution: safer materials/processes (water-based vs. solvent-based).
- Engineering Controls: guarding, ventilation, automation, isolation.
- Administrative Controls: SOPs, permits, job rotation, signage, training.
- PPE: the last line of defense, not the first.
Digital enforcement: ePTW prevents work from starting until all pre-conditions, isolations (via LOTO (Lock Out Tag Out)), and approvals are complete. Mobile apps ensure field crews see the current permit, isolation points, and gas test results.
Compliance snapshot
- UK/Europe: Align controls with risk assessment duties; maintain records, training, and competence proof.
- US: Ensure program elements map to OSHA expectations—hazard communication, hearing conservation, lockout/tagout, confined spaces, and recordkeeping.
- Global: Document the rationale for controls, keep SDS current, and retain evidence of inspections and corrective actions.
ToolKitX helps with auditable trails, versioned policies, and training completions so you’re inspection-ready—any day.
Operational KPIs to track
- Leading indicators: inspections completed on time, % actions closed within SLA, gas tests recorded, pre-task briefs conducted.
- Lagging indicators: TRIR/LTIFR by area, near-miss to incident ratio, repeat findings.
- Program health: permit cycle time, isolations verified, overdue training, contractor compliance.
Dashboards in ToolKitX turn these into at-a-glance signals and nudge owners before gaps become incidents.
Digital tools that de-risk high-hazard work
- ePTW (electronic permit-to-work): formalizes approvals for hot work, confined space, live electrical, work at height.
- LOTO (Lock Out Tag Out) (Lockout/Tagout): digital isolation plans, authorized personnel, verification photos, energy checks.
- HSE & inspections: mobile checklists, issue capture, CAPA workflows, risk registers.
- Training & competency: role-based training, reassessments, certificates, expiry alerts.
- Lone-worker safety: GPS check-ins, man-down detection, SOS escalation.
Bringing it together
Classify hazards, identify them consistently, assess risk with a simple matrix, and enforce the hierarchy with digital gates. That’s how you cut incidents, pass audits, and speed safe work—without slowing the job. ToolKitX gives you the workflows and evidence trail to make it stick in the field.
Book a free demo now @ https://toolkitx.com/contactform.html