Common Mistakes in HIRA and How to Avoid Them
A Hazard Identification and Risk Assessment (HIRA) is one of the most powerful tools in occupational health and safety management. It helps organizations proactively identify hazards, evaluate their risks, and implement appropriate control measures to prevent accidents.
However, in many workplaces, the HIRA process is treated as a formality — a “checklist exercise” rather than a living system. This often results in ineffective assessments, missed hazards, and incomplete control measures that can lead to accidents or near-misses.
In this guide, we’ll cover:
- What HIRA is and why it’s important
- The most common mistakes made during HIRA
- Practical ways to avoid those mistakes
- Best practices for improving your HIRA process
Let’s start with a quick refresher.
What is HIRA?
HIRA stands for Hazard Identification and Risk Assessment. It’s a systematic process used to:
- Identify potential hazards in the workplace.
- Evaluate the associated risks.
- Implement control measures to reduce risks to acceptable levels.
Key Objectives of HIRA
- Prevent workplace incidents by proactive risk management.
- Create awareness among employees about hazards and controls.
- Ensure compliance with local safety laws and international standards.
- Support continuous improvement of the safety management system.
Example:
In a construction site, hazards may include:
- Working at height → Risk: Falling → Control: Use of fall protection PPE.
- Hot work → Risk: Fire → Control: Fire extinguisher, Hot Work Permit.
- Excavation → Risk: Collapse → Control: Shoring and benching.
Why Do Mistakes Happen in HIRA?
Despite being a structured process, HIRA can go wrong due to several factors:
- Lack of experience or training.
- Poor team collaboration.
- Time pressure and documentation mindset.
- Failure to update after workplace changes.
- Treating HIRA as a paper exercise rather than a practical tool.
These mistakes can lead to undetected hazards, underestimated risks, and ineffective control measures — increasing the likelihood of accidents.
Common Mistakes in HIRA and How to Avoid Them
Let’s look at the most frequent errors safety professionals and organizations make during HIRA — and how to correct them effectively.
Mistake 1: Treating HIRA as a Paperwork Exercise
Description:
Many organizations conduct HIRA only to meet legal or client requirements. The assessment is often copied from old projects or done by a single person in an office without visiting the site.
Consequences:
- Hazards are missed because actual working conditions are not considered.
- Risk ratings are inaccurate.
- Workers remain unaware of the real risks they face.
How to Avoid:
Conduct site visits and engage with workers directly during hazard identification.
Treat HIRA as a live document that guides daily operations.
Review and update it regularly as site conditions change.
Integrate HIRA outcomes into toolbox talks and job planning meetings.
Mistake 2: Incomplete Hazard Identification
Description:
One of the most critical failures in HIRA is not identifying all possible hazards — especially hidden or indirect ones.
Example:
During welding, the obvious hazard (burns) might be identified, but indirect hazards such as fumes, UV radiation, and confined space oxygen depletion are often missed.
Consequences:
- Inadequate control measures.
- False sense of safety.
- Accidents from overlooked hazards.
How to Avoid:
Use structured techniques like:
- Job Safety Analysis (JSA)
- Process Hazard Analysis (PHA)
- Checklists for mechanical, chemical, electrical, and ergonomic hazards.
Involve multi-disciplinary teams (operators, supervisors, safety officers).
Walk through each step of the activity (task-based analysis).
Mistake 3: Incorrect Risk Evaluation
Description:
Risk evaluation often goes wrong when the likelihood or severity of a hazard is guessed rather than analyzed based on data.
Example:
Assessing electrical shock as “low risk” just because it has never happened before — ignoring that the severity could be fatal.
Consequences:
- Misleading risk ratings.
- Critical hazards not prioritized for control.
How to Avoid:
Use a standardized risk matrix combining likelihood and severity.
Refer to past incident data, near-misses, and industry statistics.
Always assume worst-case credible scenarios for severity.
Cross-check risk ratings with the team for accuracy.
Mistake 4: Over-Reliance on PPE
Description:
Some HIRA reports simply list “Use PPE” as the only control measure for every hazard. PPE is often treated as a universal fix — which it isn’t.
Consequences:
- Ignores higher levels of control (engineering, administrative).
- Workers exposed to unnecessary risks.
- Non-compliance with the Hierarchy of Controls principle.
How to Avoid:
Follow the Hierarchy of Risk Controls:
- Elimination
- Substitution
- Engineering controls
- Administrative controls
- PPE (last line of defense)
Use PPE only when other controls are not feasible.
Clearly define PPE type, standard, and maintenance requirements.
Mistake 5: Copy-Paste or Generic HIRA
Description:
A major issue in many organizations — the same HIRA is reused across multiple projects without considering site-specific conditions.
Example:
Using the same HIRA for tower crane erection and scaffold installation, despite different hazards and control requirements.
Consequences:
- Fails to capture unique hazards.
- Misleads teams about actual risks.
- Violates regulatory compliance.
How to Avoid:
Develop activity-specific HIRAs (Excavation, Working at Height, Hot Work, etc.).
Conduct pre-job hazard assessments (PJHA) before starting any new work.
Review and update the HIRA when the environment, equipment, or process changes.
Mistake 6: Poor Team Involvement
Description:
HIRA is often done by the safety officer alone, without involving the people who actually perform the work.
Consequences:
- Lack of ownership among employees.
- Missing practical insights about real hazards.
- Ineffective implementation of controls.
How to Avoid:
Include cross-functional representatives — supervisors, workers, engineers, and maintenance teams.
Conduct open discussions to gather inputs during hazard identification.
Encourage feedback and improvement suggestions after implementation.
Mistake 7: Ignoring Non-Routine Activities
Description:
HIRAs frequently overlook non-routine tasks such as equipment maintenance, cleaning, or shutdown activities.
Consequences:
- Hidden risks during infrequent jobs.
- Increased accident potential during maintenance or shutdowns.
How to Avoid:
Develop separate HIRAs for maintenance, shutdown, and emergency operations.
Include tasks like confined space entry, chemical handling, or lifting operations.
Review risks before each non-routine job using Task-Based Risk Assessment (TBRA).
Mistake 8: Poor Documentation and Version Control
Description:
Some organizations fail to maintain proper records, revisions, or version tracking of their HIRA documents.
Consequences:
- Confusion about which version is current.
- Missed updates or outdated control measures.
- Compliance issues during audits.
How to Avoid:
Use version numbers, revision dates, and authorization signatures.
Maintain both soft and hard copies securely.
Archive old versions for reference and learning.
Mistake 9: No Follow-Up or Monitoring
Description:
Even a perfect HIRA loses value if corrective actions are not implemented or reviewed. Many assessments end once the paperwork is submitted.
Consequences:
- Control measures not applied.
- Repeated incidents due to unaddressed hazards.
- Loss of trust in the safety system.
How to Avoid:
Develop an Action Tracking System for all HIRA recommendations.
Assign responsibilities and deadlines.
Review implementation progress during safety meetings.
Audit effectiveness through site inspections.
Mistake 10: Failure to Communicate and Train
Description:
HIRA results often stay confined to management or safety teams. Workers performing the jobs are not aware of identified risks or control measures.
Consequences:
- Workers unknowingly engage in unsafe practices.
- Ineffective risk controls due to lack of awareness.
How to Avoid:
Use HIRA findings in Toolbox Talks and Induction Training.
Display major hazards and controls at work locations.
Train employees on safe work procedures derived from HIRA.
Encourage reporting of new hazards by workers.
Example: Poor vs. Effective HIRA
| Criteria | Poor HIRA | Effective HIRA |
|---|---|---|
| Hazard Identification | General hazards listed | Task-specific, detailed hazards identified |
| Risk Rating | Based on assumption | Based on actual likelihood and severity |
| Control Measures | Only PPE mentioned | Hierarchy of Controls followed |
| Team Involvement | Safety officer only | Cross-functional team |
| Documentation | Generic template | Project-specific HIRA with version control |
| Implementation | Ends with submission | Monitored and reviewed regularly |
Tips for Improving HIRA Effectiveness
- Start Early: Conduct HIRA at the planning stage, not after work begins.
- Be Practical: Include realistic, achievable controls that workers can apply.
- Engage Workers: Use toolbox talks and briefings to update teams on HIRA findings.
- Integrate Technology: Use HIRA software or digital templates for accuracy and version control.
- Review After Incidents: Update HIRA based on lessons learned from near misses or accidents.
- Train the Assessors: Conduct periodic refresher training for those performing HIRAs.
- Link HIRA to Permits: Ensure HIRA findings reflect in the Permit-to-Work system.
- Encourage Ownership: Make every employee responsible for hazard identification.
HIRA Quality Checklist
Before approving a HIRA, verify the following:
All hazards (physical, chemical, biological, ergonomic, psychosocial) identified
Risk levels assigned using approved matrix
Controls aligned with the hierarchy of controls
Team members participated and signed off
Implementation responsibilities assigned
HIRA reviewed by competent authority
Reviewed after site condition changes
Case Example: Learning from a Real Incident
Incident:
A maintenance worker was burned while repairing a valve containing residual hot oil.
Root Cause:
HIRA listed “Burn injury” but did not mention residual heat during maintenance. Isolation procedures were not implemented.
Lessons Learned:
- HIRA should cover all stages — before, during, and after the task.
- Include residual and secondary hazards.
- Validate HIRA through field verification and supervision.
Corrective Action:
Updated HIRA with “Residual Energy” hazards and trained workers on lockout/tagout (LOTO) before maintenance.
Internal Links
- Fire Risk Assessment in the Workplace – Complete Guide
- Emergency Response Plans: What Every Facility Should Include (and Often Misses)
- Behavior Based Safety Programs: How to Design, Implement, and Sustain for Workplace Excellence
- Top 10 Common Errors During Risk Assessments and How to Avoid Them
- Internal vs External Audits: Best Practices and Pitfalls for Safety Professionals
External References
Conclusion
A HIRA is not just a compliance requirement — it’s a critical safety tool that can prevent serious accidents if done effectively.
Most HIRA failures arise from human error, poor engagement, or lack of follow-up, not from the process itself.
By avoiding the common mistakes discussed — such as generic templates, incomplete hazard identification, and poor implementation — organizations can make their HIRA a living document that drives real safety improvements.
Remember: A well-executed HIRA is the foundation of every safe workplace.
