Here are the facts and myths about appropriate PPE
Understand critical factors for selecting and using PPE to ensure you’re choosing the right equipment that meets regulatory standards and protects workers from hazards.
Learning Objectives
- Recognize that personal protective equipment (PPE) is the last line of defense in protecting workers from hazards, not the primary mode.
- Understand that PPE selection should be based on the risks associated with a task.
- Identify appropriate PPE to stock at your facility based on the diversity of the workplace as well as the facility’s unique hazards.
PPE insights
- There are many considerations for when personal protective equipment (PPE) should be used in the workplace.
- PPE should be selected based on identified hazards at the facility.
- It’s important to consider workers’ body shapes and sizes when purchasing PPE.
Most people understand the critical importance of personal protective equipment (PPE) in protecting workers from hazards that cause serious injury and illness. But with all the products available on the market today, many environmental, health and safety (EHS) practitioners don’t know where to begin or feel overwhelmed when it comes to choosing PPE.
According to the U.S. Occupational Health and Safety Administration (OSHA), employers should have PPE programs if PPE is used at their facility. PPE programs are ultimately responsible for addressing the hazards present in the workplace; the selection, maintenance and use of PPE; the training of workers on its use; and the monitoring of the program’s effectiveness.
Choosing the right PPE equipment and making sure it’s used properly is one of the most important things a company can do to protect itself and its workers. One barrier to selecting PPE is a limited understanding of how to choose the most effective equipment for the workers and facility. Which PPE is chosen can depend on various factors, such as the hazards workers are exposed to, the preferences of the workers and the availability of PPE equipment.
In many cases, though, decision-makers choose PPE based solely on cost without adequately considering the workplace hazards or other factors that may impact their use. What’s worse, decision-makers may rationalize their choices through various PPE myths. Dispelling these misconceptions and understanding the critical factors impacting PPE selection and use will ultimately help PPE programs and practitioners choose the right PPE equipment that meets regulatory requirements and protects workers from hazards.
Myth No. 1: PPE is the first line of defense to protect workers from hazards.
PPE is actually the last line of defense for protecting workers from hazards and should only be used after all other options for preventing exposure have been exhausted. In fact, PPE programs should be part of a much bigger hazard identification and risk reduction program, where a comprehensive approach is used to identify risks and protect workers. Programs should:
- Conduct a job hazard analysis or task hazard analysis to identify the hazards associated with each workplace process and activity.
- Use the hierarchy of controls to determine if the hazards can be eliminated, substituted or engineered out. A matrix can help identify potential mitigation actions and the type of PPE based on the hazard. For some examples of how to implement the hierarchy of controls, see Table 1.
- Evaluate and recommend PPE necessary to mitigate any residual risk that cannot be eliminated, substituted or engineered out.
Table 1: Examples for implementing the hierarchy of controls | ||||
Hazard | Eliminate | Substitute | Engineer | PPE |
Noise from compressor | Can the compressor be removed from the building? | Can a newer, quieter model be used instead of an outdated compressor? | · Establish a dedicated compressor room
· Hang noise-reducing blankets around compressor. |
Earplugs or muffs |
Hazardous chemical splash while filling tank | Hard pipe chemical feed into tank so personnel aren’t manually filling the tank | Is there a safer chemical that could be used in the batch instead? | Automate valves once all tank connections are made, removing personnel exposure. | Goggles or face shield, gloves, apron |
Toxic gas inhalation during sampling | Collect a sample without exposing personnel, using a robot or automatic means. | Is there a safer chemical that could be used instead? | Perform sampling under a hood or in a well-ventilated area. | Respirator |
Myth No. 2: All PPE is created equal.
PPE supplied by different vendors varies in quality, style, rating and functionality. K-95 masks are a great example of this. During the COVID-19 pandemic when N-95 masks were in short supply, people started using K-95 masks even though K-95 and N-95 masks are not made to the same standard. K-95 masks are made to the Chinese standard, while N-95s are made to the National Institute for Occupational Safety and Health standard. What’s more, some masks looked like K-95 masks but were not manufactured to either standard.
PPE should be carefully selected based on the identified hazards at the facility, making sure it conforms to appropriate standards (e.g., OSHA, American National Standards Institute, American Society for Testing and Materials) rather than looking for the lowest-cost items. Choosing low-cost PPE options cost more money in the long run.
Remember the saying, “You get what you pay for.” PPE that costs less per unit quantity may also be low-quality, which may be more prone to failure. If PPE fails more frequently, workers will use more, which will ultimately cost more. Frequent failure can lead to more incidents and accidents and a higher OSHA recordable incident rate, all of which will result in more money spent on medical expenses.
Poor-quality and inappropriate PPE can also impact worker acceptance. Workers have their own requirements for PPE comfort, perceived effectiveness and durability. If they don’t like the PPE, don’t trust it or feel it hinders them from doing their job, then they won’t wear it. And if they don’t wear the PPE, the facility’s accident incidence rate and medical costs may go up.
Myth No. 3: Workers not wearing PPE causes many accidents.
This is an insidious misconception that blames workers for incidents rather than seeing it as something the facility can change or control. A good root cause analysis doesn’t blame the worker and instead digs deeper to find out which process failed and what can be fixed or changed to prevent the accident from recurring.
When asked why they weren’t wearing their PPE, workers will often say they forgot, which doesn’t get to the core of the issue. When encouraged to explain further, many cite a host of underlying issues, including poor quality, unreliability or they just don’t like it. PPE needs to be acceptable to workers in the following areas:
- Comfort. PPE must be comfortable for employees to wear. A facility PPE team can sample different PPE and make recommendations on the most comfortable options. Diverse representation is critical because what’s comfortable for one size, gender or body shape may not be comfortable for another.
- Quality and reliability. Workers become frustrated by PPE that consistently fails and breaks. Collect data from your facility on PPE failure and reordering rates. Then, interview employees regarding their perceptions about the PPE quality. Ask them about their PPE concerns and the kinds of PPE they would prefer. Finally, conduct an analysis of the data and evaluate whether a better PPE selection should be offered.
- Flexibility. Workers will be consistently unhappy if PPE interferes with them doing their jobs. Convene a PPE team consisting of representatives from every area of the facility. Ask them what they want in terms of PPE and what their current concerns are with existing PPE options.
- Size. If the right sizes aren’t available, workers won’t be able to wear the PPE. Make sure you order a variety of sizes (i.e., XS to XXL) to choose from.
- Style. Workers often use PPE to express their own uniqueness and style. If they perceive the PPE as ugly, clunky or boring, they won’t use it. Try offering PPE in a variety of colors, brands and form factors. A brand or style that works well for one worker may not work well for another.
Myth No. 4: One glove is as good as another.
Gloves are designed for specific hazards. A cut-resistant leather glove, for example, will do little to protect employees from impact hazards. Before purchasing gloves for your facility, identify the types and severity of hazards. Then, select gloves that appropriately protect personnel from those hazards (see Table 2).
Table 2: Glove protection based on type, rating and material | ||||
Protection type | Rating | Rating explanation | Standard | Material |
Cut resistance | A1 to A9 | A1=Least resistant
A9=Most resistant |
ANSI 105 | Leather, chain mail, para-amid (i.e., Kevlar), high-performance polyethylene (HPPE) |
Puncture resistance | 0 to 5 | 0=Least resistant
5=Most resistant |
ANSI 105
|
Para-amid, HPPE |
Abrasion resistance | 1 to 6 | 1=Least resistant
6=Most resistant |
ANSI 105
|
Leather, para-amid, HPPE |
Impact protection | 1 to 3 | 1=Least protective
3=Most protective |
ANSI 105
|
Thermoplastic rubber |
Chemical resistance | 1 to 6
|
Breakthrough Time: 1=Least protective
6=Most protective |
EN 374 | Latex, nitrile, neoprene, rubber, butyl, linear low-density polyethylene, polyvinyl chloride, polyvinyl alcohol |
A to C | Chemical Permeation:
A=Most protective C=Least protective |
|||
Biological activity protection | Bacteria, fungi and/or virus | N/A | EN 374 | Latex, nitrile, rubber |
Heat protection | 0 to 5
|
0=Least protective
5=Most protective |
ASTM F1060
|
Leather, terrycloth, aramid, acrylic, aramax |
1 to 4 | 1=Least protective
4=Most protective |
EN 407 | ||
Electrical insulation | Class 00 to 4 | 00=Least insulating
4=Most insulating |
ASTM D120 | Rubber |
Myth No. 5: One size fits all (or most).
People come in a variety of shapes and sizes. There’s no such thing as “one size fits all.” Even hearing protection comes in different sizes for different-sized ear canals. Workers are more inclined to wear their PPE if it fits properly, is comfortable and is perceived as body-flattering.
PPE suppliers are stepping up and offering a variety of shapes, sizes, proportions and colors. PPE suppliers are also recognizing that PPE designed for men does not adequately fit all genders. Best practice is to order and stock multiple sizes for each type of PPE so employees can find a size that fits their body. This applies to safety vests, gloves, hearing protection, smocks, aprons and safety shields/glasses. If your facility provides pants, shirts, coveralls or other types of clothing, make sure your facility orders appropriate sizes and styles for the entire workforce.
Myth No. 6: Safety glasses protect your eyes from all hazards.
Just as with gloves, different eye protection is designed to protect employees from different hazards. If your employees routinely work with liquids, safety shields are probably not the best choice, as they do not protect from liquid ingress on the top or sides. Better choices would be goggles or a face shield. The ANSI Z87 standard is what OSHA cites in 29 CFR 1910 for eye and face protection, which includes goggles and face shields.
Identify the types of face and eye hazards at your facility and then identify the appropriate type of safety glasses, goggles or shields to protect workers from those hazards. Keep in mind that different types of safety glasses may be needed at different locations within the facility (see Table 3).
Table 3: Eye protection | |||
Protection | Description | Type | Example uses |
Impact | Protection from flying solid objects | Z87 or Z87+
(high impact) |
Woodworking, grinding, machining, sawing, drilling |
Chemical | Protection from splashes | D3 | Lab environment, degreasing, chemical exposure |
Dust | Protection from suspended dust | D4 or D5 | Sanding, woodworking, buffing |
Light | Protection from light-emitting sources | U = UV protection | Outdoor work |
L = Visible light | Blue light protection with high computer use | ||
W = Welding | Welding |
Myth No. 7: Workers know which protective shoes to buy.
Workers may be overwhelmed walking into a shoe store and seeing the variety of brands, styles and safety ratings. While employers often allow workers to purchase their own foot protection and be reimbursed for it, many employers do not clearly communicate the expectations for the type of foot protection that employees should be purchasing.
A variety of options can help address this problem, including:
- On-site visits from shoe companies. Some shoe companies offer “shoe-mobiles” or other means of offering a curated selection of work shoes that meet the employer’s requirements. That way, workers can only select from approved footwear.
- Provide visual guidance. Many companies provide useful written instructions for purchasing shoes that include the standards and ratings. However, workers may not bring this guidance with them or fail to recall the full instructions. For example, they may remember that the shoe must be ASTM-rated but not recall the specifics. Best practice is for employers to supply a picture of the label on the shoe so that workers can use that picture to match it at the store.
A comprehensive PPE program
A manufacturing or industrial facility’s PPE program should be part of a much bigger hazard identification and risk-reduction program. The PPE program should identify the residual hazards in each process that have not been mitigated via elimination, substitution or engineering.
The EHS practitioner should be one member of the PPE team, which meets periodically to evaluate PPE offerings and identify the types of PPE offered to employees. The representatives of the PPE team should listen to the concerns and input of others in their work area and bring those concerns to the PPE team as a means of continuous improvement. The PPE offered to the workforce should be based on the hazards as well as on employees’ sizes, shapes, styles and preferences.
Gayle Nicoll, PhD, REP, ASP, CSP, is a process safety services expert with Jensen Hughes.
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