Guide
Risk Assessment Example: Step-by-Step Guide
A practical risk assessment example with the 5-step process — identify hazards, assess risks, implement controls, record findings, and review. Includes a worked example you can adapt.
7 min readUpdated July 2026
The 5-Step Risk Assessment Process
- Identify hazards: What could cause harm? Walk the workplace, consult workers, review incident history, and check manufacturer documentation.
- Assess risks: For each hazard, evaluate the likelihood of harm and the severity of consequences. Assign a risk rating.
- Implement controls: Apply the hierarchy of controls to eliminate or reduce the risk.
- Record findings: Document the hazards, risk ratings, and controls. Communicate to all affected workers.
- Review: Reassess when conditions change, after incidents, or at scheduled intervals (e.g., annually).
Hierarchy of Controls
Controls should be applied in this order, from most to least effective:
- 1. Elimination — remove the hazard entirely (e.g., relocate work away from the hazard)
- 2. Substitution — replace the hazard with something less dangerous (e.g., use water-based paint instead of solvent-based)
- 3. Engineering controls — isolate people from the hazard (e.g., guards, interlocks, ventilation)
- 4. Administrative controls — change how people work (e.g., procedures, training, permits)
- 5. PPE — personal protective equipment (last line of defence, not the primary control)
Risk Matrix
| Likelihood ↓ / Consequence → | Minor (First aid) | Moderate (Lost time) | Serious (Hospital) | Catastrophic (Fatality) |
|---|---|---|---|---|
| Almost certain | Medium | High | Extreme | Extreme |
| Likely | Medium | High | High | Extreme |
| Possible | Low | Medium | High | Extreme |
| Unlikely | Low | Low | Medium | High |
| Rare | Low | Low | Low | Medium |
Worked Example: Pump Maintenance
Task:
Replace the mechanical seal on a centrifugal pump handling hot water (80°C) at 6 bar.
Hazards identified:
- • Hot water — thermal burns (80°C water can cause 3rd-degree burns in 1 second)
- • Pressurised system — water under 6 bar pressure can cause injection injury
- • Electrical energy — the pump motor is energised
- • Manual handling — the pump casing is heavy
- • Slips — water on the floor from the repair
Risk ratings (before controls):
- • Hot water: Possible / Serious = High
- • Pressurised system: Possible / Catastrophic = Extreme
- • Electrical: Likely / Catastrophic = Extreme
Controls implemented:
- • Electrical isolation (LOTO) — eliminates electrical risk
- • Close suction and discharge valves — isolate from system pressure
- • Open drain valve — verify zero pressure before opening casing
- • Allow pump to cool — wait until surface temperature is below 40°C
- • Wear heat-resistant gloves and face shield during disassembly
- • Use mechanical lifting aid for the pump casing
- • Clean up water spills immediately — use absorbent material
Risk ratings (after controls):
All risks reduced to Low through elimination (isolation) and engineering/administrative/PPE controls.