Hazard Identification and Risk Assessment for COR#

Executive Summary#

Hazard identification and risk assessment form the foundation of any effective health and safety management system—and are heavily weighted in COR (Certificate of Recognition) audits. For ICI subcontractors, this means implementing systematic processes to identify workplace hazards, assess risks, and document the analysis. This guide explains COR requirements for hazard identification, practical approaches to job hazard analysis (JHA), and documentation best practices.

Hazard Identification in the COR Framework#

COR audits evaluate hazard identification and assessment as a core element, examining:

Element 3: Hazard Identification and Assessment - Does the company have systematic processes to identify hazards? Are assessments documented? Do workers participate?

Element 4: Hazard Control - Once hazards are identified, are controls implemented? Is the hierarchy of controls followed?

These elements are interconnected—you can't implement effective controls without first identifying hazards, and identification is meaningless without follow-through to control.

COR auditors look for evidence that hazard identification is:

Systematic - Not random or reactive, but built into operations
Comprehensive - Covering all work activities and locations
Documented - Creating records for audit and improvement
Participatory - Involving workers who do the work
Ongoing - Continuously updated as conditions change

Types of Hazard Assessment#

ICI subcontractors typically need multiple types of hazard assessment:

Baseline Hazard Assessment#

A comprehensive assessment of all workplace hazards associated with the company's operations. This assessment:

Identifies all tasks and activities performed
Catalogs hazards associated with each activity
Establishes standard controls for routine hazards
Serves as the foundation for safe work procedures

Baseline assessments are typically done once and updated periodically or when operations change significantly.

Job Hazard Analysis (JHA)#

Task-specific assessments that break down work activities into steps and identify hazards at each step. JHAs are the most common hazard assessment tool for ICI subcontractors and are typically required:

Before starting work at a new job site
When tasks or conditions change significantly
When new equipment or processes are introduced
Following incidents or near-misses

Pre-Task Planning#

Shorter, more immediate assessments conducted before specific work begins—often called "Take 5" or similar. These quick assessments:

Review immediate conditions before starting work
Identify any new hazards not covered in the JHA
Confirm controls are in place and understood
Engage workers in hazard awareness at the task level

Workplace Inspections#

Regular inspections that identify new or emerging hazards:

Formal scheduled inspections
Informal daily walk-throughs
Equipment-specific inspections
Post-incident inspections

Conducting Effective Job Hazard Analyses#

JHAs are the workhorse of hazard identification for ICI subcontractors. An effective JHA process includes:

Step 1: Select the Task#

Choose tasks for analysis based on risk factors:

Injury history (tasks where incidents have occurred)
Potential severity (tasks that could cause serious harm)
Frequency (tasks performed often)
Complexity (tasks with many steps or variables)
New or changed (tasks that are unfamiliar)

For ICI subcontractors, priority tasks often include:

Working at heights (scaffolding, ladders, aerial lifts)
Hot work (welding, cutting, brazing)
Confined space entry
Working with hazardous materials
Heavy lifting and material handling
Working near energized equipment

Step 2: Break Down the Task#

List the sequential steps required to complete the task. Be specific enough to identify hazards at each step, but not so detailed that the analysis becomes unwieldy.

A mechanical insulation task might break down as:

Transport materials to work area
Set up scaffolding/access
Prepare substrate surface
Measure and cut insulation
Apply adhesive/fasteners
Install insulation
Apply jacketing/cladding
Clean up and demobilize

Step 3: Identify Hazards#

For each step, identify hazards that could cause harm. Consider:

Hazard Category	Examples
Struck by/against	Falling objects, moving equipment, sharp edges
Falls	From heights, same-level trips and slips
Caught in/between	Machinery, materials, collapse
Overexertion	Heavy lifting, awkward positions, repetitive motion
Exposure	Chemicals, noise, temperature extremes
Electrical	Contact, arc flash
Fire/explosion	Hot work, flammable materials

Step 4: Assess Risk#

Evaluate the risk level of each hazard by considering:

Likelihood - How probable is it that harm will occur?
Severity - If harm occurs, how serious would it be?
Exposure - How many workers are exposed and how often?

Risk assessment can be qualitative (high/medium/low) or semi-quantitative (numeric scales). The goal is prioritizing hazards for control.

Step 5: Determine Controls#

For each hazard, identify controls following the hierarchy of controls:

Elimination - Remove the hazard entirely
Substitution - Replace with less hazardous alternative
Engineering controls - Physical barriers, guards, ventilation
Administrative controls - Procedures, training, signage
PPE - Personal protective equipment as last resort

Document specific controls for each identified hazard.

Step 6: Document and Communicate#

The completed JHA should be:

Documented in a standard format
Reviewed with all workers performing the task
Signed by workers acknowledging understanding
Retained for audit and reference

Documentation Requirements for COR#

What JHA Documentation Should Include#

Element	Purpose
Task/activity description	Identifies what's being assessed
Location/job site	Establishes site-specific context
Date of assessment	Shows currency
Assessor(s)	Establishes accountability
Worker participants	Demonstrates involvement
Task steps	Shows systematic analysis
Hazards identified	Documents findings
Risk assessment	Shows prioritization
Controls specified	Documents response
Worker acknowledgment	Confirms communication

Organizing JHA Records#

For COR audit purposes, JHAs should be organized so that:

Records for any job site can be retrieved
Records for any task type can be retrieved
Chronological progression can be demonstrated
Worker participation can be verified

Many subcontractors organize by job site, with JHAs filed by date within each site folder. This allows auditors to pull all hazard assessments for a specific project.

Linking JHAs to Work Activities#

JHAs should be completed before related work begins and should reflect actual work conditions. COR auditors may compare:

JHA dates vs. work start dates (was assessment done first?)
JHA content vs. actual conditions (does it reflect real hazards?)
JHA controls vs. workplace observation (are controls implemented?)

Common Hazard Categories for ICI Subcontractors#

Working at Heights#

For mechanical insulation, sheet metal, and HVAC contractors, working at heights is often the primary hazard. JHAs should address:

Fall hazards from scaffolding, ladders, and aerial lifts
Falling object hazards to workers below
Access and egress hazards
Weather-related hazards (wind, ice, rain)
Structural integrity of work platforms

Hot Work#

Welding, cutting, brazing, and similar operations present multiple hazards:

Fire and explosion from ignition sources
Burns from hot materials and equipment
Respiratory hazards from fumes and gases
Eye injuries from radiation
Electrical hazards from welding equipment

Material Handling#

Moving insulation materials, sheet metal, and equipment creates:

Musculoskeletal hazards from lifting and carrying
Struck-by hazards from materials and loads
Laceration hazards from sharp edges
Vehicle/pedestrian interaction hazards

Hazardous Materials#

Depending on the work, subcontractors may encounter:

Insulation fibers (respiratory and dermal hazards)
Adhesives and sealants (chemical exposure)
Existing hazardous materials (asbestos, lead, mold)
Cleaning chemicals and solvents

Environmental Hazards#

ICI job sites present environmental hazards:

Noise from equipment and operations
Temperature extremes (indoor and outdoor)
Poor lighting conditions
Confined spaces
Working near other trades

Worker Participation in Hazard Identification#

COR places significant emphasis on worker participation. Auditors assess whether workers are genuinely involved in identifying hazards—not just signing forms prepared by supervisors.

Effective Worker Involvement#

During JHA development - Workers who perform the task should participate in developing the JHA. They understand the actual work conditions better than anyone in the office.

During pre-task reviews - Before starting work, crews should review the JHA together, with workers identifying any conditions that differ from the assessment.

Ongoing hazard reporting - Workers should have mechanisms to report new hazards discovered during work. These reports should result in documented updates to hazard assessments.

Inspection participation - Workers should participate in workplace inspections, contributing their observations of hazards and concerns.

Evidence of Worker Participation#

COR auditors look for evidence such as:

Worker signatures on JHAs (not just acknowledgment, but participation)
Documented hazard reports from workers
Interview responses showing workers contribute to hazard identification
Observation of workers engaged in pre-task planning

Corrective Action and Follow-Through#

Hazard identification is only valuable if it leads to action. COR auditors examine:

Control implementation - Are the controls specified in JHAs actually implemented? If a JHA requires fall protection, are workers using it?

Corrective action tracking - When inspections or hazard reports identify problems, is there a system to track resolution?

Continuous improvement - Are JHAs updated based on experience? Do lessons from incidents lead to revised hazard assessments?

Common Audit Findings#

COR auditors frequently identify hazard identification issues:

Generic JHAs - Assessments that don't reflect actual job site conditions. A JHA developed in the office that workers sign without site-specific review.

Missing documentation - Work performed without documented hazard assessment. JHA dates that postdate work start dates.

No worker involvement - JHAs developed by supervisors or safety staff without input from workers performing the tasks.

Risk assessment gaps - Hazards identified but risk levels not assessed, making prioritization impossible.

Control implementation failures - Controls specified in JHAs but not implemented in the field. PPE requirements listed but workers not wearing required equipment.

No updates - JHAs that haven't been revised despite changed conditions, new incidents, or updated procedures.

How Appello Supports Hazard Identification#

Appello's Safety & Forms module supports systematic hazard identification with customizable JHA forms that can be completed in the field from mobile devices.

The form builder supports the structured hazard assessment process—task steps, hazard categories, risk assessment scales, and control documentation. Conditional logic can prompt additional questions based on identified hazards, ensuring thorough assessment.

Completed JHAs are stored centrally with timestamps and geolocation, demonstrating when and where assessments were conducted. Worker acknowledgment signatures are captured digitally, creating audit-ready documentation of both participation and communication.

For COR audit preparation, hazard assessments can be retrieved by job site, date range, or task type, enabling efficient response to auditor requests.

Conclusion#

Hazard identification and risk assessment are not administrative exercises—they're the foundation of protecting workers from harm. COR certification recognizes this by making hazard assessment a core evaluation element.

For ICI subcontractors, effective hazard identification means:

Systematic JHA processes for all significant tasks
Genuine worker participation in identifying hazards
Documented assessments completed before work begins
Controls implemented consistently in the field
Continuous improvement based on experience and incidents

The documentation requirements for COR can feel burdensome, but the underlying purpose is ensuring workers go home safely. A well-implemented hazard identification program reduces injuries while creating the records needed for COR compliance.

Related Reading:

Hazard Identification and Risk Assessment for COR