Personal protective equipment (PPE) is there to keep people safe, plain and simple. But even when it’s being worn, that doesn’t always mean it’s being used correctly. Whether it’s poor fit, wrong choices, or just everyday oversights, small PPE mistakes can lead to big risks on the job.
Here’s a look at some of the most common mistakes people make with PPE, and what to do instead.
1. Skipping Eye Protection That Actually Works
Let’s start with one of the most overlooked parts of PPE: vision. Just wearing something over your eyes isn’t enough. If the glasses fog up, slip off, or cause discomfort, they’ll either get tossed aside or fail when it matters.
And for workers who already wear glasses? That’s where things get even riskier. Layering standard safety goggles over regular glasses can distort vision, reduce reaction time, and even cause headaches.
The better solution is to invest in prescription safety glasses. These are made specifically for people who need vision correction on the job, and they’re designed to meet safety standards while staying comfortable for long hours. When eye protection fits right and helps you see clearly, it’s way more likely to be worn properly and consistently.
2. Wearing PPE That Doesn’t Fit Right
PPE is not one-size-fits-all, but it’s surprising how often people end up with gear that clearly doesn’t fit.
Oversized gloves can catch on machinery. Loose-fitting harnesses won’t hold in a fall. And helmets that sit too high or slide around won’t protect the head properly.
Fit isn’t just about comfort, it’s about protection. If gear moves around or gets in the way of work, it becomes a hazard itself. Workers should be properly sized and fitted for all PPE, and that includes checking fit regularly as bodies change and gear wears out.
3. Using Damaged or Expired Equipment
PPE isn’t meant to last forever. Even high-quality gear breaks down with use and exposure to the elements. Helmets can become brittle. Gloves wear thin. Respirators degrade.
But in busy environments, it’s easy to grab whatever’s nearby, even if it’s past its prime.
There should be a clear process for inspecting gear before use. If something’s damaged, it needs to be taken out of circulation immediately. No “just one more time” thinking. That’s when things go wrong.
And when it comes to PPE like respirators, expiration dates matter. Components like filters and elastic parts can lose effectiveness, even if they look fine.
4. Skipping PPE for “Quick Tasks”
One of the most dangerous assumptions on a worksite is thinking, “It’s just for a second.”
Cutting a corner without gloves. Stepping into a zone without a helmet. Not bothering with ear protection because the noise “won’t last long.” These little decisions often lead to some of the worst injuries.
PPE is there for the unexpected. If you knew exactly when and where an accident was going to happen, you wouldn’t need it. But nobody does.
Whether the job takes 10 minutes or two hours, the rules should be the same. PPE is a requirement, not a suggestion—even for “just this once.”
5. Not Wearing PPE the Right Way
Sometimes PPE is technically being worn, but it’s still not doing its job.
Think about:
- Hard hats worn backward (without a reversible suspension system)
- Masks that don’t seal properly around the nose and mouth
- Gloves removed for phone use and then not put back on
- Safety vests unzipped or left hanging open
Improper use of PPE gives a false sense of security. People may think they’re protected when they’re not, which can be more dangerous than not wearing any at all.
Training needs to include how to properly wear each piece of gear, and there should be regular checks to make sure it’s happening.
6. Treating PPE as a “One-and-Done” Solution
PPE is the last line of defense, not the only one. Too often, it’s treated as the catch-all answer to every risk.
But hazards should first be reduced or eliminated wherever possible. That means engineering controls, safer procedures, and better planning. PPE comes in after all that, to protect from what’s still unavoidable.
When the focus is only on handing someone a helmet or a pair of gloves, it puts too much pressure on that single layer of protection. And if something fails or isn’t worn perfectly, there’s nothing left to fall back on.
Good safety programs make PPE part of the plan, not the whole plan.
Keeping Safety Real
PPE isn’t just a checkbox. It’s about real people staying safe in real environments.
Making sure it fits. Making sure it’s worn right. Making sure it’s the right gear in the first place. All of that matters.
When those small mistakes are caught and corrected, it helps prevent the big ones. And in safety, that can make all the difference.
