The Most Common PPE Mistakes Employees Make Every Day

Personal protective equipment is one of the most visible parts of workplace safety.

Safety boots. Hard hats. Gloves. Safety glasses. Reflective clothing. Hearing protection. Respirators. Harnesses.

Most workplaces have rules telling employees what PPE they need to wear.

But there's an important question that is often overlooked:

Are employees using their PPE correctly?

Simply having PPE available does not guarantee effective protection. PPE needs to be appropriate for the hazard, properly fitted, correctly used, maintained and replaced when necessary.

Here are some of the most common PPE mistakes employees make during everyday work.

1. Not wearing PPE because the task is "quick"

A common attitude is:

"I'm only going to be there for a minute."

Unfortunately, the duration of a task doesn't determine whether a hazard exists.

An employee who enters an area without the required eye, head, hand, hearing or respiratory protection can still be exposed to the hazard, even if the task takes less than a minute.

Better practice: PPE requirements should be based on the hazard and the task, not how long the employee expects to be exposed.

2. Wearing PPE incorrectly

PPE can only provide its intended protection when it is worn and adjusted correctly.

Common examples include:

• Wearing a hard hat incorrectly.
• Leaving safety glasses on top of the head.
• Wearing gloves that are too large.
• Failing to adjust a harness correctly.
• Wearing hearing protection incorrectly.
• Leaving protective clothing open or improperly fastened.

Poor fit can reduce protection and may create additional problems for the wearer.

3. Using the wrong PPE for the hazard

Not all PPE provides the same protection.

A glove designed for general handling isn't automatically suitable for chemical exposure. A pair of safety glasses isn't necessarily appropriate for every eye hazard.

PPE selection should consider the nature of the hazard, the work being performed, physical effort, duration of use, comfort, visibility and compatibility with other PPE. South Africa's Physical Agents Regulations specifically identify these factors when selecting PPE.

4. Using damaged or worn PPE

Employees sometimes continue using PPE because it "still looks usable."

But cracks, tears, frayed straps, worn surfaces and other forms of deterioration can compromise protection.

PPE should be inspected regularly, and employees should understand the signs that indicate equipment needs to be removed from service.

When in doubt, don't simply carry on using it.

5. Skipping the pre-use inspection

A pre-use inspection doesn't have to be complicated.

Before putting on PPE, employees should check whether it is:

• Suitable for the task.
• In good condition.
• Clean and hygienic where required.
• Complete.
• Properly fitted.
• Within its useful life.

Training should cover how employees inspect PPE for wear or damage, as well as how to put it on, adjust it, remove it and care for it.

6. Choosing comfort over protection

Comfort is important.

If PPE is uncomfortable, employees may be more likely to adjust it incorrectly, remove it or avoid wearing it.

But comfort should be considered alongside protection, not instead of it.

The right approach is to select PPE that provides the required protection while also considering fit, comfort, visibility, communication and the physical demands of the job.

7. Failing to maintain PPE

PPE doesn't maintain itself.

Depending on the equipment, employees may need to clean, inspect, store or otherwise maintain it according to workplace procedures and manufacturer instructions.

Reusable PPE should be kept hygienic and in proper working order, while disposable PPE needs appropriate disposal.

8. Storing PPE incorrectly

Where PPE is stored can affect its condition.

Leaving equipment exposed to unnecessary contamination, heat, moisture, chemicals or physical damage can shorten its useful life.

Employees should know where PPE belongs when it isn't being used and how it should be stored.

9. Combining PPE without checking compatibility

Employees may need to wear several types of PPE at once.

For example:

Hard hat + hearing protection + eye protection + respirator

Each item might be suitable individually, but that doesn't automatically mean the combination will work properly.

PPE selection should consider compatibility where multiple items are required.

10. Thinking PPE is someone else's responsibility

Employers have responsibilities around providing appropriate PPE, information, instruction, training, supervision and enforcement.

Employees also have an important role.

They need to use PPE as instructed, look after it, report problems and follow workplace safety procedures.

A strong PPE programme therefore isn't simply about issuing equipment.

It is about making sure employees understand why it is required and how to use it properly.

How can employers reduce PPE mistakes?

A PPE programme should go further than handing employees a pair of safety glasses and telling them to wear them.

Consider:

1. Train employees properly

Training should cover when PPE is required, what PPE is required, correct fitting and adjustment, limitations, inspection, maintenance, storage and replacement.

2. Demonstrate, don't just explain

Show employees how equipment should be worn and adjusted.

This is particularly important for equipment where incorrect fitting can significantly reduce protection.

3. Include PPE in toolbox talks

PPE doesn't need to be a once-a-year discussion.

Use short toolbox talks to address real observations from your workplace.

For example:

"We've noticed several employees aren't adjusting their hearing protection correctly. Let's look at the correct method."

That's much more useful than simply saying:

"Remember to wear your PPE."

4. Inspect PPE regularly

Supervisors should look for damaged, unsuitable or incorrectly used equipment during normal workplace inspections.

5. Ask employees what isn't working

If employees repeatedly remove a particular item of PPE because it is uncomfortable, interferes with communication or doesn't fit correctly, don't immediately assume the problem is employee behaviour.

Investigate whether the PPE selection is appropriate.

PPE should be the last thing employees think about, not the last thing employers think about

Good PPE management is not about creating a workplace where employees are constantly being told:

"Put your PPE on."

It's about creating a workplace where employees understand the hazard, understand the protection required and know how to use that protection correctly.

PPE is an important part of workplace risk management, but it should not replace efforts to eliminate or control hazards wherever reasonably practicable. South African OHS requirements place the emphasis on controlling hazards before relying on PPE as the primary solution.

The next time you walk through your workplace, don't only ask:

"Are employees wearing PPE?"

Ask:

"Are they wearing the right PPE, in the right way, and is it still capable of doing its job?"

That question can reveal much more about the effectiveness of your PPE programme.