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Level 3: Personal Protective Equipment (PPE)

Last Line of Defense​

PPE provides barrier between worker and hazard but does not eliminate or reduce hazard itself.

[!important] Last Resort PPE is least effective control. Use only after higher-level controls implemented or while higher controls being developed.

Why PPE is Least Effective​

Limitations:

Doesn't Remove Hazard:

  • Hazard still present
  • If PPE fails, full exposure occurs

Relies on Correct Use:

  • Must be worn properly and consistently
  • Gaps, improper fit reduce effectiveness dramatically
  • Human error common

Provides No Protection When Not Worn:

  • Workers may remove during breaks but remain in hazardous area
  • Discomfort leads to non-compliance

Requires Maintenance:

  • Must be kept clean, undamaged
  • Regular replacement needed
  • Storage affects lifespan

Protects Only Individual:

  • Each person needs own PPE
  • Doesn't protect others nearby

When PPE Appropriate​

Supplement to higher controls:

  • Additional protection where engineering controls reduce but don't eliminate risk
  • Example: Respirator while using on-tool dust extraction (belt and suspenders)

Residual risks:

  • Low-level risks remaining after engineering controls
  • Example: Safety glasses when working with hand tools

Temporary protection:

  • While developing/installing engineering controls
  • Emergency situations

Short-duration, low-frequency tasks:

  • Where engineering controls not reasonably practicable
  • Combined with administrative controls

Types of PPE​

Head Protection​

Hard Hats (AS/NZS 1801):

  • Protects from falling objects, head strikes
  • Mandatory on construction sites
  • Types: General purpose, high-impact, electrical insulating

Selection:

  • Certified to Australian Standard
  • Appropriate for hazards (electrical work requires electrical-rated)
  • Correct size, adjustable suspension

Maintenance:

  • Inspect daily (cracks, dents, degradation)
  • Replace after impact
  • Replace every 2-5 years (UV degradation)

Eye and Face Protection​

Safety Glasses (AS/NZS 1337):

  • Impact protection (flying particles, dust)
  • Side shields recommended

Goggles:

  • Better seal around eyes
  • Protection from dust, chemical splash, molten metal

Face Shields:

  • Full face protection
  • Grinding, chemical handling, welding
  • Use with safety glasses (additional protection)

Welding Helmets:

  • Protect from arc radiation, sparks, spatter
  • Auto-darkening or passive lens

Selection based on hazard:

  • Impact: Safety glasses/goggles
  • Chemical splash: Goggles/face shield
  • Welding: Welding helmet with correct shade

Hearing Protection​

Earplugs:

  • Inserted in ear canal
  • Disposable foam or reusable pre-molded
  • Typical attenuation: 20-30dB
  • Require correct insertion (training)

Earmuffs:

  • Cups over ears
  • Typical attenuation: 20-35dB
  • Easier to achieve good seal
  • More visible (supervision easier)

Selection:

  • Calculate required attenuation (noise level - 85dB)
  • Comfort (more likely to be worn)
  • Compatible with other PPE (hard hat, safety glasses)

See Noise Management.

Respiratory Protection​

Disposable Respirators (P1, P2, P3):

  • P1: Nuisance dusts (limited protection)
  • P2: Mechanically generated particles (construction dust, wood dust)
  • P3: Toxic particles, very fine particles

Half-Face/Full-Face Respirators:

  • Reusable facepiece with replaceable cartridges/filters
  • Cartridge type depends on contaminant (particulate, organic vapor, acid gas)

Powered Air-Purifying Respirators (PAPR):

  • Battery-powered fan draws air through filter
  • Positive pressure (better protection, more comfortable)
  • For high-exposure situations

Supplied-Air Respirators:

  • Continuous fresh air supply via hose
  • For very high-exposure or oxygen-deficient atmospheres

Critical Requirements:

  • Fit testing (quantitative testing to ensure seal)
  • Clean-shaven (facial hair prevents seal)
  • Medical clearance (breathing resistance)
  • Training in use, limitations, maintenance

When Required:

  • Silica dust exposure (P2 minimum, often PAPR for engineered stone)
  • Welding fumes (P2)
  • Asbestos work (P1 or P2 depending on work)
  • Chemical vapors (appropriate cartridge)

See Silica Dust.

Hand Protection​

Gloves - select for specific hazard:

Cut-resistant: Handling sharp materials (glass, metal)

Chemical-resistant: Specific chemical (check SDS):

  • Nitrile (oils, solvents, some chemicals)
  • PVC (acids, bases)
  • Neoprene (broader chemical resistance)
  • Butyl rubber (specific chemicals)

Impact-resistant: Operating vibrating equipment

Thermal: Hot surfaces, cold environments

General purpose: Light mechanical work

Limitations:

  • Reduce dexterity
  • May get caught in machinery (don't use near rotating parts)
  • Must be correct material for chemical (wrong glove = no protection)

Foot Protection​

Safety Boots (AS/NZS 2210):

  • Steel or composite toe cap (crush protection)
  • Penetration-resistant sole (nails, sharp objects)
  • Slip-resistant sole
  • Mandatory on construction sites

Additional features:

  • Electrical hazard protection
  • Metatarsal protection (top of foot)
  • Ankle support

High-Visibility Clothing​

AS/NZS 4602:

  • Day use (fluorescent material)
  • Night use (retroreflective tape)
  • Mandatory on construction sites

Purpose:

  • Ensure workers visible to plant operators, vehicles
  • Critical for traffic areas

Fall Protection PPE​

Full-Body Harness:

  • With shock-absorbing lanyard or self-retracting lifeline
  • Anchor point required
  • Rescue plan mandatory

See Falls from Heights.

Other PPE​

Protective Clothing:

  • Coveralls (dust, chemical splash)
  • Aprons (chemical handling, welding)
  • Sun protection (broad-brim hats, long sleeves)

Knee Pads:

  • For kneeling work (tiling, flooring)
  • Reduces knee strain and injury

PPE Management​

Selection​

Match PPE to hazard:

  • Assess hazard (what protection needed?)
  • Consult Australian Standards
  • Check manufacturer specifications
  • Consider compatibility with other PPE

Involve workers:

  • Trial different options
  • Comfort affects compliance
  • Get feedback

Provision​

Employer must provide:

  • PPE at no cost to worker
  • Correct type and size
  • Adequate quantities
  • Replacement when worn/damaged

Training​

Workers must be trained:

  • What PPE required and why
  • How to wear correctly (fit testing for respirators)
  • How to inspect for damage
  • When to replace
  • Limitations of PPE
  • Storage and maintenance

Maintenance​

Regular:

  • Cleaning (according to manufacturer instructions)
  • Inspection before each use
  • Storage in clean, dry location
  • Replacement schedule

Replace when:

  • Damaged
  • Degraded (UV, chemicals, age)
  • After significant impact (hard hats)
  • Filters/cartridges exhausted

Monitoring Compliance​

Supervisors check:

  • PPE being worn
  • Worn correctly
  • Appropriate for hazard
  • Good condition

Non-compliance:

  • Understand why (discomfort, doesn't fit, not available?)
  • Address underlying issues
  • Reinforce importance

Practical Construction Example​

Task: Grinding concrete (silica dust, noise, flying particles)

Controls Implemented:

Engineering (Level 2):

  • Wet grinding with water suppression
  • On-tool vacuum extraction
  • Work outdoors (natural ventilation)

Administrative (Level 3):

  • SWMS prepared
  • Trained operator
  • Time limits (1-hour blocks, rotation)

PPE (Level 3):

  • P2 respirator (fit-tested) - silica dust protection
  • Safety glasses with side shields - flying particles
  • Earmuffs (Class 4, 28dB attenuation) - noise protection (grinder 100dB)
  • Gloves - vibration reduction, hand protection
  • Hard hat, safety boots, hi-vis - general construction PPE

Result: Multiple layers of protection. Engineering controls reduce silica and noise exposure. PPE provides additional protection if engineering controls not 100% effective.

Summary​

PPE:

  • Last line of defense
  • Does not eliminate hazard
  • Only effective if worn correctly and consistently
  • Requires selection, training, maintenance, monitoring
  • Always supplement to higher-level controls

Key Principle: PPE protects the worker, not the workplace. Use PPE only after implementing elimination, substitution, isolation, and engineering controls.