Man sitting on stairs holding his back, with a folder and papers on the floor.

HSE figures show 124 worker fatalities in 2024/25. Most incidents are preventable. This guide turns UK legal duties and best practice into clear, actionable steps you can apply now.

Work-related injuries damage lives, morale and operations. A structured approach, rooted in the Hierarchy of Controls, legal duties, and worker involvement, reduces risk and improves productivity.

Hierarchy of controls (best → least effective)

Control levelWhat good looks like
EliminateRemove the hazard/task entirely (e.g., off-site fabrication instead of hot-work on site).
SubstituteUse safer materials/processes (low-tox product instead of solvent; mechanical lift for heavy items).
EngineeringPhysical changes: fixed guards/interlocks, LEV for dust/fume, edge protection, vehicle–pedestrian segregation.
AdministrativePermits to work, safe systems, toolbox talks, supervision, rota/rotation, clear signage and site rules.
PPETask-appropriate, fit-tested, maintained PPE. Always the last line of defence.

Risk assessment in 5 steps (MHSWR)

  1. Identify hazards (people, place, process, plant, product).
  2. Decide who might be harmed and how (employees, contractors, visitors, public, lone workers).
  3. Evaluate risk & select controls using the hierarchy; prioritise high risks.
  4. Record & implement—proportionate documentation; communicate changes; assign owners/dates.
  5. Review after incidents/near-misses/changes or at planned intervals.

HSE guidance: 5 steps to risk assessment •
MAC tool (manual handling) •
RAPP tool (pushing/pulling)

Training & competence (what “good” looks like)

  • Induction: site rules, emergency, reporting/near-miss, PPE, basic hazards.
  • Role training: WAH, manual handling, PUWER authorisations, COSHH, traffic routes, lone working.
  • Refreshers: e.g., annual WAH/manual handling; face-fit annually; First Aid requalification every 3 years.
  • Verification: observed practice/spot checks; signed toolbox talks; competence recorded.
  • Consultation: involve workers/safety reps; lift issues via regular safety huddles.

Equipment & maintenance (PUWER/LOLER)

Select, maintain and inspect equipment. Do pre-use checks; schedule servicing; complete statutory thorough examinations (LOLER) and LEV testing. Keep records. Technology (e.g., proximity alarms, telemetry) can help, but CCTV should be framed as a monitoring/investigation aid, not a primary control.

For small businesses lacking in-house expertise, external support (e.g., a competent safety adviser or a local insurance broker) can check that policy conditions align with your risk profile and legal duties.

Expert view: insurance pitfalls after safety changes

“After a serious incident, insurers look for two things; material changes you didn’t tell them about, and policy conditions you didn’t meet. Keep clear evidence of maintenance and statutory checks (PUWER/LOLER/LEV), act on risk-improvement notes, and notify significant changes promptly—new processes,
heat work, contractors, or layout. It lowers risk and helps avoid disputes at claim time.”

  • Document everything: pre-use checks, thorough examinations, servicing, and corrective actions.
  • Tell your insurer/broker about changes: sums insured, business activities, occupancy, security.
  • Align practice with policy: permit-to-work, hot-work precautions, contractor controls, alarm testing.

Use the HSE Stress Management Standards to assess
Demands, Control, Support, Relationships, Role and Change. Practical steps:

  • Workload reviews, clear priorities, sensible overtime limits.
  • Visible manager support; MHFAiders; confidential referral routes.
  • Anti-bullying/harassment policy; fair procedures; return-to-work support.

What to measure (leading & lagging)

  • Leading: % closed actions from risk assessments; near-miss reporting rate; toolbox-talk completion; audit scores; overdue maintenance.
  • Lagging: LTIFR; RIDDOR rate; days lost; repeat incidents.
  • Set monthly targets; discuss results at safety meetings; publish a one-page dashboard internally.

Executive checklist (print and pin)

  • [ ] Appoint a competent person; set a 12-month safety plan with KPIs.
  • [ ] Complete/review risk assessments (5 steps); apply the control hierarchy.
  • [ ] Confirm compliance: WAH, PUWER/LOLER, COSHH, Fire, First Aid; document evidence.
  • [ ] Build a training matrix with refresh cycles; record competence/authorisations.
  • [ ] Enable near-miss & hazard reporting (simple, no-blame); act on trends.
  • [ ] Schedule maintenance & inspections (PUWER/LOLER/LEV) with reminders.
  • [ ] Consult workers & safety reps; hold monthly safety reviews.
  • [ ] Implement stress risk assessment and support pathways.
  • [ ] Track leading/lagging indicators; share lessons learned.
  • [ ] Review insurance after material changes; check policy conditions/notifications.

FAQs

How often should we review risk assessments?

After any change/incident/near-miss and at planned intervals (at least annually for higher-risk work).

What counts as a RIDDOR report?

Specified injuries, over-7-day absences, occupational diseases, dangerous occurrences and certain public injuries. See HSE’s RIDDOR guidance.

What is a “competent person” under MHSWR?

Someone with the training, experience and knowledge to assist in applying the law and managing risks (can be internal or external).

Is PPE enough?

No. PPE is the last line of defence. Always try to eliminate, substitute or engineer out risks first.

Key UK regulations & HSE topics (quick reference)

Editor’s note: This article is general guidance, not legal advice. Always consult the official HSE pages and your competent adviser.

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