How to Perform a Comprehensive Activity Hazard Analysis (AHA)

OSHA says that identifying and mitigating hazards in the workplace is crucial to maintaining a safe environment (OSHA, n.d.). In the Army we used Activity Hazard Analysis (AHA) to identify and control hazards. Conducting an AHA systematically helps ensure you’re taking proactive measures to prevent incidents. If you’ve been looking for a reliable way to assess and mitigate hazards using FM 385, I can guide you through the process, step by step (U.S. Army Corps of Engineers, 2014).

An Activity Hazard Analysis (AHA) is a systematic process used to identify potential hazards associated with a specific task, assess the risks, and implement controls to mitigate those risks. Following the guidelines set out in FM 385 ensures that hazards are addressed before work begins, helping to create a safer work environment.

Activity Hazard Analyses (AHA) are not just about compliance; they’re about creating safer, more efficient workplaces. With the right approach, you can ensure that your workers are protected from the start. Let’s walk through the AHA process as outlined by FM 385 and explore how to implement it effectively in your organization.

Step 1: Understanding the Basics of Activity Hazard Analysis

An Activity Hazard Analysis (AHA) involves breaking down a task into its components, identifying the hazards associated with each step, and implementing controls to mitigate those hazards. The AHA process is essential for high-risk activities and is mandated by many regulatory frameworks, including FM 385-1-1, which outlines safety standards for federal projects and construction.

The key components of an AHA include:

1. Task Breakdown: Clearly define the steps of the task or activity.
2. Hazard Identification: Identify potential hazards for each step.
3. Risk Assessment: Evaluate the likelihood and severity of each hazard.
4. Control Measures: Implement controls to mitigate the identified risks.
5. Review and Monitoring: Continuously monitor the activity to ensure controls are effective.

Step 2: Conducting a Task Breakdown

To start an AHA, you need to break the task down into manageable steps. This allows you to analyze each part of the activity for potential hazards. The task breakdown should be detailed enough to capture the risks at each stage but not so granular that it becomes overwhelming. For example, if the task is “roof installation,” the breakdown might include steps such as setting up scaffolding, carrying materials to the roof, and securing roofing tiles.

• Pro Tip: Involve the people who regularly perform the work in this process. They have invaluable insight into the nuances that others might overlook.

Step 3: Identifying Hazards

Once the task is broken down, the next step is to identify the potential hazards associated with each activity. Hazards can be physical, chemical, biological, or ergonomic, depending on the nature of the task. Common hazards include:

• Falls from height during roofing activities.
• Chemical exposure when handling hazardous materials.
• Repetitive strain injuries in tasks that require heavy lifting.

For each task step, list out every possible hazard. Be thorough, as even seemingly minor risks can escalate into major incidents without proper controls.

Step 4: Assessing the Risks

With the hazards identified, it’s time to assess the risk of each one. Risk assessment typically involves two factors:

1. Likelihood: How likely is it that the hazard will cause an incident?
2. Severity: How severe would the consequences be if the hazard led to an incident?

Using a risk matrix, you can classify risks as low, medium, or high. This prioritization helps determine which hazards need immediate attention and which can be managed with standard controls.

• Example: If workers are installing roofing tiles at height, the risk of falling might be classified as high, given the likelihood and severity of a fall-related injury.

Step 5: Implementing Control Measures

Once the risks have been assessed, the next step is to put control measures in place to mitigate those risks. The hierarchy of controls should guide this process, starting with the most effective methods. The Hierarchy of Controls is a systematic approach to minimizing or eliminating hazards in the workplace. It ranks controls from the most effective to the least effective. Here are the levels, starting with the most preferred method:

1. Elimination
   Completely remove the hazard.
   This is the most effective method, as it physically removes the hazard from the workplace. For example, replacing a hazardous chemical with a non-hazardous one.
2. Substitution
   Replace the hazard with something less dangerous.
   Substitution involves replacing the hazardous substance, process, or material with a safer alternative. For example, using a less toxic chemical in a process.
3. Engineering Controls
   Isolate people from the hazard.
   This includes physical changes to the workplace or the environment to reduce exposure. Examples include machine guards, ventilation systems, and noise-dampening materials.
4. Administrative Controls
   Change the way people work.
   These controls focus on altering how work is performed to reduce risks. Examples include rotating shifts to reduce exposure times, implementing standard operating procedures (SOPs), training, and signage.
5. Personal Protective Equipment (PPE)
   Protect the worker with protective gear.
   PPE is considered the least effective because it does not eliminate the hazard and relies on proper use by employees. Examples include gloves, safety glasses, hard hats, and respirators.

For example, if the hazard is falling from heights, the control measures might include using fall protection systems, ensuring guardrails are in place, and requiring workers to wear harnesses.

Note: The Hierarchy of Controls displayed as an inverted pyramid. The most effective control, Elimination, is at the top, followed by the less effective methods down to Personal Protective Equipment (PPE) at the bottom.

Step 6: Review and Continuous Monitoring

The AHA doesn’t end once control measures are implemented. Ongoing review and monitoring are critical to ensure that the controls are working effectively. Supervisors should regularly inspect the worksite, check equipment, and talk to workers to confirm that safety measures are being followed.

If new hazards emerge during the task, the AHA should be revisited, and additional controls should be implemented as necessary. Continuous monitoring ensures that safety measures adapt to changing conditions and prevent complacency from setting in.

Additional Considerations for Activity Hazard Analysis

1. Documentation
   Documenting the AHA process is essential for accountability and compliance. The documentation should include the task breakdown, identified hazards, risk assessments, and the control measures implemented. This not only ensures compliance with FM 385 but also serves as a reference for future AHAs and safety audits.
2. Worker Involvement
   Involving workers in the AHA process promotes a safety culture and ensures that the analysis reflects real-world conditions. Workers are more likely to follow safety procedures if they have contributed to the process and understand the reasoning behind the controls.
3. Training
   Effective training is essential to ensure that workers understand the AHA and how to implement the control measures. Training sessions should include hands-on demonstrations of PPE use, emergency procedures, and safe work practices specific to the task at hand.

Conclusion

Performing a comprehensive Activity Hazard Analysis (AHA) using FM 385 is a critical step in ensuring workplace safety. By systematically identifying hazards, assessing risks, and implementing control measures, you can prevent incidents before they happen. Remember, an AHA is a living document that requires continuous review and adaptation. By actively involving workers, maintaining proper documentation, and staying vigilant, you can create a safer work environment and meet the highest safety standards.

References

U.S. Army Corps of Engineers. (2014). Safety and health requirements manual (EM 385-1-1). U.S. Army Corps of Engineers. https://www.usace.army.mil/Safety-and-Occupational-Health/Safety-and-Health-Requirements-Manual/

Occupational Safety and Health Administration (OSHA). (n.d.). Hazard Identification and Control Best Practices. https://www.osha.gov/safety-management/hazard-Identification