When it comes to workplace safety, Personal Protective Equipment (PPE) is the final line of defense between a worker and a serious injury. Yet even the best PPE can fail if it’s used incorrectly—or not at all. OSHA reports thousands of preventable injuries each year caused by improper PPE selection, usage, or maintenance.
This guide breaks down the top 10 PPE mistakes that put workers at risk, and what safety managers and workers need to do right now to fix them.
1. Wearing the Wrong Type of PPE
Different jobs call for different protection. Using the wrong PPE can be just as dangerous as not wearing any.
- Wearing cloth or basic work gloves to handle chemicals.
- Using dust masks instead of NIOSH-approved respirators around toxic fumes.
- Putting on basic safety glasses instead of sealed splash goggles when working with corrosives.
How to avoid it: Match PPE to the actual hazard, not just the task title. Follow OSHA 29 CFR 1910 Subpart I and relevant ANSI standards when selecting protective equipment.
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2. Ignoring Fit and Sizing
If PPE doesn’t fit, it doesn’t protect. Gloves that are too loose can slip, safety glasses that sit crooked can leave gaps, and respirators that don’t seal can allow dangerous air in.
How to avoid it:
- Provide multiple sizes, not “one size fits all.”
- Perform required fit testing for respirators under OSHA 1910.134.
- Recheck fit if workers’ weight, facial hair, or facial structure changes.
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3. Failing to Inspect PPE Regularly
PPE breaks down with use. Cracked shells, torn stitching, or worn-out padding all reduce protection. A hard hat with a hairline fracture is not “still good.” It’s a hazard.
How to avoid it:
- Inspect PPE before every use, not once a month.
- Replace equipment that is damaged, not “almost damaged.”
- Store PPE in clean, dry conditions away from direct heat and chemicals.
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4. Not Replacing Expired PPE
Yes, PPE expires. Materials like rubber, plastic, elastic, and filters degrade over time. A helmet left in a hot truck for a year is no longer the same helmet you issued.
How to avoid it:
- Create a PPE log that tracks issue dates and expiration/shelf life intervals.
- Follow manufacturer recommendations for replacement timelines.
- Remove expired gear from circulation so it doesn’t get “loaned out” to new hires.
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5. Wearing PPE Incorrectly
Even correct PPE can fail if it’s worn the wrong way. Common examples include earplugs that aren’t fully inserted, chin straps left hanging, or gloves worn over contaminated sleeves.
How to avoid it:
- Demonstrate correct wear and fit during safety meetings.
- Have supervisors and leads spot-check compliance at the job site.
- Correct bad habits immediately—don’t let “quick shortcuts” become culture.
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6. Skipping PPE Training
Issuing gear is not the same thing as training. Many companies hand workers PPE and assume they “know what to do.” OSHA doesn’t see it that way, and neither should you.
OSHA 1910.132(f) requires employers to train employees on:
- When PPE is necessary
- What PPE is necessary
- How to properly put on, take off, adjust, and wear it
- Limitations of the PPE
- Proper care, maintenance, and disposal
How to avoid it: Build PPE training into onboarding and repeat it annually or whenever the job task or hazard changes.
7. Not Cleaning or Maintaining PPE Properly
Dirty PPE doesn’t just look bad—it can be dangerous. A dust-choked respirator is harder to breathe through. Greasy gloves can transfer chemicals or fuel skin irritation. Scratched eyewear can reduce visibility and increase eye strain.
How to avoid it:
- Follow the manufacturer’s cleaning instructions (not guesswork).
- Let PPE air-dry; don’t bake it on a heater or dashboard.
- Assign PPE to individuals where appropriate to reduce cross-contamination risk.
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8. Overlooking Compatibility Between PPE Items
PPE doesn’t exist in isolation. Sometimes one protective item interferes with another. For example:
- Earmuffs that block a respirator’s straps from sealing properly.
- Safety goggles that get pushed upward by a hard hat brim.
How to avoid it: Test PPE combinations during real work positioning, not just in the break room. Consider integrated systems (helmet/face shield/ear protection combos, full-face respirators, etc.). Workers should never have to “choose which body part to protect today.”
9. Reusing Disposable PPE
Disposable PPE is called “disposable” for a reason. Reusing single-use gloves, disposable masks, shoe covers, or coveralls increases exposure risk, spreads contamination, and creates a false sense of security.
How to avoid it:
- Train workers on what is single-use versus reusable.
- Provide clearly marked disposal bins on site.
- Make it easy for workers to access fresh PPE when they need it.
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10. Neglecting to Enforce PPE Policies
One of the biggest failures is cultural: rules exist, but leadership doesn’t enforce them. Workers skip PPE because “it’s just a quick task,” and nobody corrects it.
How to avoid it:
- Make PPE part of job performance expectations, not optional “extra credit.”
- Have supervisors model correct PPE use at all times.
- Reward teams for consistent compliance and low incidents, not for “finishing faster.”
The Bottom Line
Every PPE mistake on this list has caused real injuries on real job sites. The good news: all 10 are preventable. The core steps are simple—select the right PPE, fit it correctly, train your people, inspect gear daily, replace it when it’s done, and enforce the standard every single shift.
Protecting workers isn’t just about following a rulebook. It’s about making sure everyone goes home in the same condition they arrived.
For OSHA-compliant PPE that helps your team stay safe and stay on the job, visit eSafetySupplies.com and outfit your crew with the right gear:
- Hand Protection & Work Gloves
- Head Protection & Hard Hats
- Safety Glasses & Goggles
- Respiratory Protection
- High-Visibility Vests
- Hearing Protection
Official OSHA Resource
For full regulatory guidance and employer responsibilities, visit OSHA.gov – Personal Protective Equipment (PPE).
People Also Ask (FAQ)
1. What are the most common PPE mistakes?
The biggest mistakes include using the wrong type of PPE for the job, wearing PPE that doesn’t fit, failing to inspect or replace damaged gear, and not wearing PPE correctly (for example, loose earplugs or partially sealed respirators). Many incidents also happen because workers were never properly trained on how or when to use PPE.
2. How often should PPE be replaced?
PPE should be inspected before every shift and replaced immediately if it’s damaged, visibly worn, or past its expiration or service life. Items like gloves and respirator filters may need frequent rotation, while hard hats and high-visibility vests should be replaced based on manufacturer guidance and site exposure conditions.
3. Can disposable PPE be reused?
No. Disposable gloves, masks, shoe covers, and coveralls are designed for single use. Reusing disposable PPE increases the risk of contamination, chemical exposure, and cross-contact between work areas.
4. Who is responsible for providing PPE?
Under OSHA’s PPE standard (29 CFR 1910.132), the employer is responsible for providing required PPE at no cost to the employee, ensuring it fits, and training workers on correct usage, limitations, and care.
5. How can companies improve PPE compliance?
Make PPE expectations crystal clear. Train employees. Enforce consistently. Keep enough inventory on site so nobody has to “borrow.” Most importantly, leadership and supervisors must wear PPE themselves—workers follow what they see, not just what they’re told.
Mick Chan is a Safety Supplies industry professional with over 15 years of hands-on experience. He specializes in OSHA compliance, PPE regulations, and bulk safety product procurement for high-risk industries. Mick earned his Bachelor’s degree in Business Administration from Cal State LA in 2013 and has been advising companies across California ever since. Born and raised in the San Gabriel Valley, he understands the safety needs of businesses in diverse urban and industrial environments. His work focuses on bridging safety compliance with practical product solutions for the modern workplace.