When incidents occur on industrial, mining, manufacturing and infrastructure projects, the investigation often identifies hazards that were already known or reasonably foreseeable.
The question is not always whether a hazard existed.
The question is often:
Why wasn't it identified early enough to influence the design, planning or execution of the project?
Modern engineering projects are becoming increasingly complex. Assets are larger, projects are delivered faster, and maintenance activities are often undertaken in operating facilities. As a result, project teams must identify and manage hazards throughout the entire asset lifecycle rather than waiting until construction or commissioning begins.
Hazard Identification Starts Long Before Construction
Many organisations still view hazard identification as a compliance exercise performed during a project review or risk workshop.
In reality, effective hazard identification should begin during concept development and continue through:
Design
Procurement
Construction
Commissioning
Operations
Maintenance
Decommissioning
Industry guidance consistently promotes identifying hazards as early as possible so risks can be eliminated through design rather than controlled later through procedures and administrative controls.
Looking Beyond Traditional Risk Assessments
Traditional risk assessments remain valuable, but they are often limited by the information available at the time.
Modern projects can benefit from a broader systems engineering approach that considers:
People
Operators
Maintainers
Contractors
Visitors
Emergency responders
Equipment
Mechanical systems
Electrical systems
Control systems
Mobile equipment
Environment
Weather
Dust
Noise
Visibility
Access constraints
Interfaces
Many incidents occur at the interface between systems rather than within individual systems.
Examples include:
Vehicle and pedestrian interactions
Maintenance access conflicts
Equipment isolation requirements
Confined space entry
Simultaneous operations
Research and industry guidance show that understanding these interfaces is a critical component of effective hazard identification.
The Role of Digital Engineering
One of the most significant developments in recent years has been the use of digital engineering tools to support hazard identification.
Engineering-grade LiDAR scanning and reality capture technologies enable project teams to create highly accurate digital representations of existing facilities.
These models can then be used to:
Validate access requirements
Review maintenance activities
Assess lifting studies
Identify clash risks
Evaluate line-of-fire hazards
Plan shutdown activities
Improve constructability reviews
Rather than relying solely on drawings or site photographs, teams can visualise actual site conditions before work begins.
Learning from Previous Projects
Many organisations have extensive experience managing hazards but fail to capture and reuse that knowledge effectively.
Lessons learned from previous projects should be incorporated into future hazard identification workshops and design reviews.
Industry guidance recommends using previous incidents, near misses and operational experience as inputs into hazard identification processes.
For engineering teams, site experience remains one of the most valuable sources of hazard awareness.
A Systems Engineering Approach
Hazard identification is not simply about creating a risk register.
It is about understanding how people, equipment, processes and environments interact throughout the life of an asset.
A systems engineering approach provides a structured framework for identifying hazards, evaluating risks and implementing controls before incidents occur.
Hamilton By Design has developed a dedicated resource discussing Systems Engineering and Hazard Identification, including practical approaches for industrial and mining projects.
👉 Read more here:
https://www.hamiltonbydesign.com.au/systems-engineering-hazard-identification/
Conclusion
The most effective hazard controls are often implemented before construction starts.
By combining engineering experience, site knowledge, digital engineering technologies and structured systems engineering methodologies, project teams can identify hazards earlier, reduce project risk and improve long-term operational outcomes.
The goal is simple:
Identify hazards before they become incidents.
Related Resources
https://www.hamiltonbydesign.com.au/systems-engineering-hazard-identification/
https://www.hamiltonbydesign.com.au/3d-reality-capture-services/
https://www.hamiltonbydesign.com.au/industrial-3d-scanning-services/
https://www.hamiltonbydesign.com.au/engineering-grade-lidar-scanning/
References
Engineers Australia – Safety in Design guidance.
Transport for NSW – Design Safety Management requirements.
NOPSEMA Hazard Identification Guidance Note.
OHS Body of Knowledge – Health and Safety in Design.
