When it comes to workplace safety, Personal Protective Equipment (PPE) is your last line of defense. Yet, many companies make common PPE mistakes that reduce its effectiveness—putting workers at risk of accidents, injuries, or even fatalities.

By understanding these mistakes and knowing how to prevent them, businesses can create safer work environments, maintain compliance, and protect their most valuable asset—their people.

Here are six common PPE mistakes and how to avoid them.

1. Choosing the Wrong Type of PPE

Not all PPE is designed for the same hazards. A worker using gloves for chemical protection won’t be safe handling sharp machinery.

Mistake: Using generic PPE for all tasks.
Solution: Conduct hazard assessments and choose PPE specifically designed for the risks—such as cut-resistant gloves, high-visibility safety vests, or respirators for airborne hazards.

Browse Carewell’s safety vests and gloves tailored for industrial safety.

2. Poor Fit and Comfort

If PPE doesn’t fit properly, workers won’t wear it consistently—or worse, they’ll remove it mid-task.

Mistake: Ordering “one-size-fits-all” PPE.
Solution: Offer different sizes and adjustable options. PPE like ergonomic helmets, breathable safety vests, and lightweight gloves make compliance easier.

3. Ignoring Maintenance and Replacement

Even high-quality PPE loses effectiveness if not maintained. Old helmets, torn gloves, and worn-out boots can fail at the worst moment.

Mistake: Treating PPE as a one-time purchase.
Solution: Schedule regular inspections and replace damaged or expired PPE promptly. Follow PPE care guidelines for longer-lasting safety gear.

4. Lack of Training on Proper Usage

Providing PPE isn’t enough. Workers must know how to use it correctly.

Mistake: Handing out PPE without training.
Solution: Conduct safety workshops to teach employees how to wear, adjust, and maintain their PPE. Reinforce correct habits through toolbox talks and refresher courses.

5. Not Considering Environmental Conditions

PPE that works indoors may fail outdoors or in extreme weather.

Mistake: Using the same PPE year-round.
Solution: Adapt PPE to the environment—such as mesh safety vests for hot weather, insulated vests for winter, or anti-fog goggles for humid conditions.

6. Failing to Involve Workers in PPE Selection

Workers are the ones wearing PPE daily—ignoring their input often leads to resistance and poor compliance.

Mistake: Choosing PPE without worker feedback.
Solution: Involve employees in trials and selection. When workers feel comfortable and heard, PPE usage rates increase dramatically.

How Avoiding PPE Mistakes Benefits Your Business

Correcting these common PPE mistakes doesn’t just improve safety—it also:

• Reduces accidents and compensation claims.
• Boosts productivity by minimizing downtime.
• Strengthens worker confidence and morale.
• Demonstrates compliance with industry standards.

At Carewell Group, we supply PPE solutions designed for durability, comfort, and compliance. By addressing these mistakes, you can build a safety-first culture in 2025 and beyond.

Carewell Group Pty Ltd
Unit 27/191, Mccredie Road, Smithfield, NSW 2164
Phone: +61 0477 123 699
Email: sales@carewellgroup.com.au | info@carewellgroup.com.au | logistics@carewellgroup.com.au