PPE Guide
Personal Protective Equipment (PPE) is the last line of defence against workplace hazards. Learn the types of PPE, when each is required, and how to use it correctly.
The Hierarchy of Controls
PPE is the last line of defence, not the first. Before relying on PPE, apply the hierarchy of controls:
- Eliminate: remove the hazard entirely. (e.g., de-energise equipment before working on it.)
- Substitute: replace the hazard with something less dangerous. (e.g., use a less toxic chemical.)
- Engineering controls: isolate people from the hazard. (e.g., guards, barriers, ventilation, interlocks.)
- Administrative controls: change how people work. (e.g., procedures, training, signs, permits.)
- PPE: equip the person to survive if exposed. (e.g., safety glasses, gloves, respirators.)
PPE is the last resort
PPE does not prevent accidents. It reduces the severity if an accident occurs. If you rely on PPE alone, without the higher controls, you are accepting that accidents will happen and hoping the PPE will be enough. Always start with elimination and engineering controls. Use PPE to fill the gaps.
Types of PPE for Industrial Maintenance
- Safety glasses: Protect against flying particles, splashes. Required when working with tools, chemicals, or pressurised systems. Must meet AS/NZS 1337.
- Face shield: Full-face protection against chemical splashes, steam, grinding debris. Worn over safety glasses.
- Hearing protection: Ear plugs or ear muffs. Required when noise exceeds 85 dB(A). Steam leaks and grinding are common high-noise activities.
- Gloves: Different types for different hazards: cut-resistant for handling sharp materials, heat-resistant for hot work, chemical-resistant for handling chemicals, insulated for electrical work.
- Safety boots: Steel-capped boots protect against dropped objects and crushing. Heat-resistant soles for hot work areas. Anti-slip for wet areas.
- Hard hat: Protects against falling objects. Required in areas with overhead work or crane operations.
- High-visibility clothing: Makes the worker visible to vehicle and crane operators. Required in traffic areas and at night.
- Respiratory protection: Dust masks, half-face respirators, or full-face respirators. Required when working with hazardous dust, fumes, or vapours. Must be correctly fitted and the correct cartridge selected.
- Fall protection: Harness, lanyard, anchor point. Required when working at heights above 2 metres without edge protection.
- Arc-rated clothing: For work on energised electrical equipment. See our Arc Flash Safety guide.
Common PPE Mistakes
- Not wearing it: PPE sitting in a locker doesn't protect anyone. The most common PPE failure is not wearing it.
- Wrong type for the hazard: Using cotton gloves for chemical handling. Using safety glasses instead of a face shield for grinding. Match the PPE to the hazard.
- Damaged PPE: Cracked safety glasses, holes in gloves, worn-out respirator cartridges. Inspect PPE before each use. Replace when damaged.
- Poor fit: Safety glasses that slip, gloves that are too loose, respirators that don't seal. PPE must fit properly to be effective.
- Not maintained: Dirty, contaminated PPE is itself a hazard. Clean PPE after use. Store properly.
- Shared PPE: Sharing PPE (especially respirators and hearing protection) spreads infections. Each worker should have their own.
Respirator fit testing
Respiratory protection requires fit testing to ensure an adequate seal between the respirator and the wearer's face. A respirator that doesn't seal leaks contaminated air through the gaps. Fit testing must be done by a competent person and repeated annually or whenever the wearer's facial shape changes (weight loss, dental work, etc.).
Tip: Make PPE easily accessible. If workers have to walk 5 minutes to get safety glasses, they won't. Stock PPE at the entrance to each work area. Use PPE stations: a cabinet with glasses, gloves, ear plugs, and dust masks at every plant entrance. The easier PPE is to access, the more consistently it will be worn.