Non-Routine Job Risk Assessment Explained
Understand non-routine job risk assessment, why it is critical, how to conduct it step by step, with examples, responsibilities, and best practices.
Most workplace accidents do not occur during routine, well-practiced activities. Instead, they often happen when workers are asked to perform non-routine jobsβtasks that are unusual, infrequent, or carried out under changed conditions. These jobs introduce unfamiliar hazards, uncertainty, and higher risk levels if not properly planned.
This is why non-routine job risk assessment is a critical element of industrial safety management. This article explains what non-routine job risk assessment is, why it is essential, how it differs from routine risk assessment, and how safety professionals can implement it effectively to prevent serious incidents.
What Is a Non-Routine Job?
A non-routine job is any task that is not part of regular, day-to-day operations or is performed under conditions different from normal work.
Non-routine jobs typically involve:
- Unplanned or emergency tasks
- Infrequent maintenance or repair work
- Temporary activities
- Changes in process, equipment, or location
- Work performed by contractors or new teams
Because workers may not be fully familiar with these tasks, the risk of error and exposure to hazards increases.
What Is a Non-Routine Job Risk Assessment?
A non-routine job risk assessment is a structured process used to identify hazards, evaluate risks, and define control measures specifically for tasks that fall outside normal operations.
Unlike routine risk assessments, which are often generic and stable, non-routine job risk assessments are:
- Task-specific
- Time-specific
- Condition-specific
Their purpose is to anticipate what could go wrong during unusual activities and ensure risks are controlled before work begins.
Why Non-Routine Jobs Are High Risk
Non-routine jobs are inherently riskier due to several factors.
Lack of Familiarity
Workers may not have prior experience performing the task, increasing the chance of mistakes.
Changed Work Conditions
Non-routine jobs often involve changes such as:
- Equipment isolation
- Temporary access platforms
- Modified workflows
- Restricted spaces
These changes introduce new hazards.
Time Pressure
Emergency or breakdown-related tasks are often rushed, leading to shortcuts and poor decision-making.
Inadequate Procedures
Standard operating procedures may not exist or may not cover the specific non-routine activity.
Increased Interaction Between Activities
Non-routine jobs often take place alongside ongoing operations, increasing the risk of simultaneous operations (SIMOPS).
Importance of Non-Routine Job Risk Assessment
Conducting a non-routine job risk assessment provides several key benefits.
Prevention of Serious Incidents
Many fatal accidents occur during maintenance, modification, or abnormal operations. Risk assessment helps identify these hazards in advance.
Better Planning and Coordination
It ensures that all steps of the job are planned and that responsibilities are clearly defined.
Improved Communication
Workers understand what they are doing, what could go wrong, and how to stay safe.
Legal and Compliance Protection
Most safety regulations require employers to assess risks, especially for non-routine and high-risk work.
Difference Between Routine and Non-Routine Job Risk Assessment
Understanding the difference helps avoid gaps in safety management.
| Aspect | Routine Job Risk Assessment | Non-Routine Job Risk Assessment |
|---|---|---|
| Frequency | Regular, ongoing | Infrequent or one-time |
| Familiarity | High | Low |
| Documentation | Often generic | Task-specific |
| Risk Level | Usually lower | Often higher |
| Review | Periodic | Before each job |
Non-routine job risk assessments require greater attention and detail.
When Is a Non-Routine Job Risk Assessment Required?
A non-routine job risk assessment is required when:
- Performing maintenance or repair work
- Carrying out emergency tasks
- Modifying equipment or processes
- Conducting shutdown or turnaround activities
- Introducing new tools or methods
- Working in unusual environments
- Using contractors for specialized tasks
In many organizations, such assessments are mandatory before permits are issued.
Types of Non-Routine Jobs Requiring Risk Assessment
Common examples include:
- Confined space entry
- Hot work outside designated areas
- Electrical isolation and testing
- Lifting non-standard loads
- Excavation near existing services
- Temporary work at height
- Commissioning and decommissioning activities
Each of these tasks carries unique hazards.
Key Elements of a Non-Routine Job Risk Assessment
An effective non-routine job risk assessment includes several essential components.
Clear Job Description
The job must be clearly defined, including:
- Scope of work
- Location
- Duration
- Equipment involved
Ambiguity leads to missed hazards.
Step-by-Step Task Breakdown
Breaking the job into steps helps identify hazards at each stage instead of treating the task as a single activity.
Hazard Identification
Hazards may include:
- Mechanical hazards
- Electrical hazards
- Chemical exposure
- Fire and explosion risks
- Environmental hazards
- Human factors
All hazards specific to the non-routine nature of the job must be identified.
Risk Evaluation
Each hazard is evaluated based on:
- Likelihood of occurrence
- Severity of consequences
This helps prioritize which risks need the strongest controls.
Control Measures
Controls are selected using the hierarchy of controls and must be specific to the task.
Authorization and Communication
The assessment must be reviewed, approved, and communicated to all involved personnel before work begins.
Step-by-Step Process for Non-Routine Job Risk Assessment
Step 1: Identify the Non-Routine Task
Confirm that the job is outside normal operations and requires special assessment.
Step 2: Assemble the Job Team
Include:
- Supervisor
- Safety officer
- Workers performing the task
- Contractors, if involved
Collaboration improves accuracy.
Step 3: Break the Job into Steps
List each step in the sequence it will be performed.
Step 4: Identify Hazards for Each Step
Ask questions such as:
- What could go wrong here?
- What is different from normal work?
- What external factors could affect this step?
Step 5: Evaluate Risks
Assess likelihood and severity for each hazard, considering worst-case scenarios.
Step 6: Define Control Measures
Specify controls such as:
- Isolation procedures
- Permit systems
- Temporary barriers
- Specialized PPE
- Supervision requirements
Controls must be practical and enforceable.
Step 7: Conduct Pre-Job Briefing
Discuss the assessment with all workers before starting work. Confirm understanding.
Step 8: Monitor and Review During Work
If conditions change, stop work and reassess risks.
Examples of Non-Routine Job Risk Assessment
Example 1: Emergency Equipment Repair
- Hazard: Unexpected equipment movement
- Risk: Serious injury
- Controls: Lockout/tagout, verification of isolation, supervision
Because the task is urgent, extra care is required.
Example 2: Temporary Work at Height
- Hazard: Fall from height
- Risk: Fatal injury
- Controls: Temporary access platform, fall protection, permit system
The temporary nature of the work introduces additional risks.
Example 3: Hot Work in a Non-Designated Area
- Hazard: Fire or explosion
- Risk: Major property damage
- Controls: Hot work permit, fire watch, gas testing
Conditions are reassessed immediately before work.
Role of Safety Officers in Non-Routine Job Risk Assessment
Safety officers play a critical role by:
- Identifying non-routine tasks
- Facilitating risk assessments
- Challenging unsafe assumptions
- Verifying control measures
- Supporting supervisors and workers
- Enforcing stop-work authority
Their experience is essential in managing non-routine risks.
Common Mistakes in Non-Routine Job Risk Assessment
Treating It as Routine Work
Assuming a task is low risk because it looks simple is a major cause of accidents.
Copying Previous Assessments
Each non-routine job is unique and requires a fresh assessment.
Rushing the Process
Time pressure should never justify skipping or shortening the assessment.
Poor Communication
If workers do not understand the risks, the assessment fails.
Best Practices for Effective Non-Routine Job Risk Assessment
To improve effectiveness:
- Always assume higher risk for non-routine tasks
- Conduct assessments at the job location
- Involve experienced workers
- Focus on worst-case scenarios
- Integrate assessments with permits
- Encourage stop-work authority
Good planning prevents poor outcomes.
Relationship with Permit-to-Work and Other Systems
Non-routine job risk assessments support:
- Permit-to-work systems
- Job safety analysis
- Method statements
- Emergency response planning
Together, these systems ensure safe execution of unusual tasks.
Legal and Compliance Importance
Many safety regulations require employers to assess risks, especially for non-routine and high-risk work. Failure to do so can result in:
- Regulatory penalties
- Project delays
- Legal liability
- Serious injuries or fatalities
Proper risk assessment demonstrates due diligence.
Conclusion
Non-routine jobs introduce uncertainty, unfamiliar hazards, and higher risk levels. Treating these tasks like routine work is a serious safety failure. Non-routine job risk assessment provides a structured way to identify hazards, evaluate risks, and implement controls before work begins. When applied consistently and practically, it protects workers, supports supervisors, and prevents serious incidents in complex industrial environments.
For checklist and templates visit The HSE Tools.
Site-Specific Risk Assessment: Why One Size Does Not Fit All
Pre-Job Risk Assessment for High-Risk Activities
Risk Rating Systems Explained for Industrial Projects
Hazard Identification Methods Used by Safety Officers
ο»ΏRisk Assessment Template for Construction Projects
Frequently Asked Questions (FAQs)
What is considered a non-routine job?
Any task that is unusual, infrequent, or performed under changed conditions compared to normal operations.
Why are non-routine jobs more dangerous?
They involve unfamiliar tasks, changed conditions, time pressure, and often lack standard procedures.
Who should conduct a non-routine job risk assessment?
Safety officers lead the process with input from supervisors, workers, and contractors.
Is non-routine job risk assessment mandatory?
In most industries, it is required under safety regulations and company procedures.
What should be done if conditions change during the job?
Work should stop, and the risk assessment must be reviewed and updated before continuing.
