Controlling hazardous substances at work

When it comes to workplace safety, especially under COSHH (Control of Substances Hazardous to Health). As an employer, it’s your responsibility to take control measures to reduce the risks of hazardous substances. Failing to do so can lead to serious health issues like respiratory diseases, skin conditions, and long-term illnesses.

But what exactly are control measures and why are they important? Let’s find out.

What is a control measure?

Simply put, a control measure is an action or safeguard put in place to reduce or eliminate risks associated with hazardous substances and dangerous work activities. In the context of COSHH control measures, they are used to prevent or minimise employee exposure to harmful chemicals, dusts, fumes and other hazardous substances.

Once you have identified the hazardous substances and conducted a COSHH assessment, your next step is to implement control measures.

Just remember that all control measures should be:

• Proportionate to the level of risk

• Reasonably practicable

Determining what’s considered 'reasonably practicable' requires balancing the risk a hazard poses with the time, money, and resources necessary to mitigate or remove that risk. When the risk is greater, it makes more sense to allocate more resources to manage it effectively.

What is the hierarchy of control measures?

Not all control measures are created equal and there is a hierarchy of control to follow. This systematic approach prioritises control methods based on their effectiveness, guiding you in implementing the most effective measures to protect your workers.

Let’s take a look at each measure in more detail: 

Elimination

This is exactly what it sounds like. It’s the complete removal of the hazard and is the best way to protect your employees.  So, if possible, stop using the substance that is harmful or stop the process that causes the substance from being produced.

For example:

In manufacturing, you could automate processes to eliminate manual handling of dangerous materials.

Substitution

If there’s no way to eliminate the hazard, substitution is the next best measure you can take. This involves replacing a hazardous substance or process with a safer alternative.

For example:

In cleaning services, you could switch to using eco-friendly, non-toxic cleaning products that are less hazardous, lowering the risk of skin and respiratory issues.

Engineering controls

What happens if there’s no way to eliminate or substitute? The next best approach is to modify the work environment to reduce exposure. The aim here is to isolate your employees from the hazard using specialised equipment or design changes.

For example:

In woodworking, you could instal Local Exhaust Ventilation (LEV) to capture dust at the source. This would reduce the risk of inhalation of fine dust particles that could lead to occupational asthma or lung diseases like COPD.

Administrative controls

Unlike an engineering control that requires equipment to reduce exposure to your employees, administrative controls involve changing the way your people work. So, it’s all about modifying work practices and policies to minimise exposure.  

For example:

In construction, you could implement mandatory safety training for all workers. This would raise awareness of hazards in the workplace and ensure that everyone knows the correct procedures for working with hazardous substances.

Personal protective equipment (PPE)

When hazards can’t be completely eliminated or controlled, employees must be provided with Personal Protective Equipment (PPE) to reduce direct exposure.

However, it’s important to not rely solely on PPE as a control safety measure. The reason PPE is at the bottom of the effectiveness scale is because collective controls tend to be more effective than individual controls. Collective measures can remove or lessen risks for your entire business, while individual measures, such as PPE, only provide protection for a single employee.

For example:

In healthcare, you could provide masks, gloves, gowns and other protective equipment to protect your employees from infections agents. This would reduce the risk of spreading infections from patients to workers.

Regularly review and maintain your control measures

Even the best control measures can become ineffective over time. That’s why regular maintenance and reviews are essential.

• In manufacturing, make sure ventilation systems are working properly, and filters are replaced on schedule.

• For cleaning teams, check that PPE like gloves and masks are in good condition.

• On construction sites, reassess dust suppression techniques to ensure they’re still effective.

Encourage employees to report issues—after all, they’re the ones using these controls every day.

Beyond the hierarchy of control measures

Despite having the best control measures in place, human error can still lead to accidents. Workers must understand the risks and know exactly how to handle hazardous substances safely.

This means training them on:

• The hazards they might encounter

• How to handle, store, and dispose of substances safely

• How to use control measures (like LEV systems or PPE)

• Emergency procedures for spills or accidental exposure

For example, if you run a lab, your staff must know how to safely handle acids and other hazardous chemicals.

Just remember that refresher training is just as important—especially if new substances or procedures are introduced. For more on why this is important, see our article on the importance of COSHH training in the workplace.

Why the control of hazardous substances is important

Failing to control hazardous substances in your workplace can lead to serious health risk, legal consequences, financial damage and a less productive workplace. In essence, it’s essential for protecting your people, business and the environment.

Let’s look at why it matters more closely:

 Protects employee health

• Prevents lung diseases (asthma, COPD) from dust and fumes

• Reduces risks of skin conditions (dermatitis , burns)

• Lowers exposure to long-term illnesses (cancer from silica)

Ensure legal compliance  with COSHH

• Avoids fines, legal action and reputational damage

• Keeps you compliant with HSE regulations

• Protects your business from costly compensation claims

Reduces workplace accidents

• Prevents fires and explosions (flammable substances)

• Lowers risks of chemical buns and toxic exposure

• Improves overall safety for employees and anyone who could be harmed

Boosts productivity and reduces sick days

• Fewer staff suffering from headaches, breathing issues, or allergies

• Reduces absenteeism and staff turnover

• Creates a happier and healthier work environment

Protects the environment

• Prevents water and soil contamination from chemical spills

• Reduces air pollution from toxic fumes

• Keep your business eco-friendly and compliant

Get help with COSHH control measures

As an employer, you have a legal and moral responsibility to protect your workers from hazardous substances under COSHH.

By identifying risks, putting the right controls in place, and staying proactive with training and monitoring, you’ll not only stay compliant but also create a safer, healthier workplace for your team.

Need help getting started? The BrightSafe Hazardous Substance Risk Assessment tool lets you quickly start addressing these challenges, letting you: 

• Create substance-specific assessments that satisfy increasingly stringent standards 

• Suggest appropriate control measures based on substance properties 

• Assign implementation tasks with clear accountability 

• Produce inspector-ready documentation in a fraction of the usual time 

See exactly how the tool addresses your specific risk areas with a short demo. No generic feature tour—just practical application to your highest-priority substances. Book your free demo.