Control of work: the foundation of safety in high-risk industries

In mining and construction, where heavy machinery, hazardous materials and complex operations converge, a single oversight can have catastrophic consequences. Control of work (CoW) systems have emerged as critical frameworks for managing these risks, providing structured approaches to ensure that every task is properly planned, authorised and executed safely.

Understanding control of work

CoW is a systematic process that governs how work activities are planned, authorised, executed and closed out in high-risk environments. Unlike simple permit-to-work systems, comprehensive CoW frameworks integrate multiple safety controls into a unified approach that manages the entire lifecycle of work activities.

At its core, CoW addresses a fundamental challenge in heavy industries; coordinating multiple contractors, managing simultaneous operations and ensuring safety measures remain effective as conditions change. In a mining operation, for example, drilling activities might need to be suspended when blasting occurs nearby, maintenance work may require isolation of equipment and ground conditions can shift unexpectedly. A robust CoW system ensures these interdependencies are recognised and managed.

Key components of effective CoW systems

A comprehensive Control of Work system typically encompasses several interconnected elements.

Work permits

Permits are the administrative backbone, documenting what work will be performed, who will perform it and what controls are required. These might include hot work permits for welding or cutting, confined space entry permits, isolation certificates for equipment maintenance or excavation permits for ground disturbance.

Risk assessments

Before any permit is issued, potential hazards must be identified in a risk assessment and controls established. In construction, this might involve assessing structural loads before heavy equipment moves onto a partially completed floor. In mining, it could mean evaluating ground stability before developing a new tunnel section.

Isolation and energy control procedures 

These procedures ensure equipment cannot unexpectedly start up or release stored energy during maintenance. This is particularly critical in industries where machinery operates under extreme conditions, such as a jaw crusher in a mine or a concrete pump on a construction site which can cause severe injury if not properly isolated.

Communication protocols

Procedures for communication ensure everyone affected by the work is informed. When one contractor's activities impact another's safety or when operations in one area create hazards for adjacent zones, effective communication becomes a life-saving control measure.

Challenges in implementation

Despite their importance, CoW systems often face implementation challenges in heavy industries. Some of these include: 

• Paper-based permit systems: bottlenecks can be created, particularly on large sites where dozens or hundreds of permits might be active simultaneously or are filed in site offices while workers are kilometres away in remote locations
• Coordination complexity: as an operation grows, maintaining oversight over people, tasks and permits becomes extremely difficult
• Cultural challenges: workers may view these systems as bureaucratic obstacles rather than essential safety tools

The digital transformation

Modern CoW systems are increasingly digital, addressing many traditional limitations.

Electronic permit systems allow real-time tracking of work activities across entire sites. Mobile applications enable workers to access permit information in the field and update status as conditions change.

Integration with other safety systems creates powerful synergies. Digital CoW platforms can link with isolation management systems to verify that equipment is properly de-energised before permits are issued. They can interface with monitoring systems in mining operations, for example, automatically suspending permits if conditions deteriorate.

Geofencing technology can create virtual boundaries around work areas, triggering alerts if personnel or equipment enter restricted zones. This is particularly valuable in open-pit mining operations where work areas span vast distances.

Best practices for success

Successful CoW implementation requires more than just procedures and technology.

Training must be comprehensive and ongoing, ensuring that workers understand not just what the requirements are, but why they exist. Site leadership must visibly support the system, holding the line when production pressures mount.

Regular audits help identify gaps between documented procedures and actual practice. These shouldn't be punitive exercises but opportunities to understand where the system isn't working and why.

Perhaps most importantly, CoW systems must be proportionate. Overly bureaucratic processes that require permits for low-risk activities breed contempt for the entire system. The goal is to focus rigour where risks are highest while maintaining efficiency for routine operations.

Boost control of work on your sites

Independently recognised by Verdantix among 44 control of work providers, Ideagen delivers proven capabilities to protect your people, equipment and operations. Contact us today to learn more and discover how easily our control of work solutions can be implemented at your organisation.

Disclaimer: This article is intended to provide general information on the subject matter. This is not intended as legal or expert advice for your specific situation. You should seek professional advice before acting or relying on the content of this information.