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Common PPE Mistakes

Most protective equipment failures are not about the gear itself. They come from choosing the wrong item, wearing it incorrectly, or using it long after it should have been replaced.

Is the gear right for the hazard?

The most common mistake is using what is on hand instead of what the task calls for. Leather gloves for liquid chemicals, a dust mask where a respirator is needed, or a bump cap where a hard hat is called for all give a false sense of safety.

Check the product label or safety data sheet and the manufacturer's information before the job. Ask OSHA, NIOSH, or your extension office if unsure.

Another version of this mistake is choosing gear because it looks similar to the correct item. Packaging can be misleading, so rely on the label rather than appearance. A related mistake is using one item for every hazard. Gloves for fencing are not the right gloves for mixing a product, and a single pair of boots rarely suits both a wet parlor and a dusty shop. Keep separate items for separate hazards and label them so that nobody grabs the wrong one in a hurry.

• Match gear to the hazard, not to convenience.
• Read the label before buying.
• Ask when unsure.

Does it fit?

Gear that is too big, too small, or loosely adjusted fails to protect and encourages people to take it off. Respirators and hearing protection are especially sensitive to fit.

Try gear on with everything else you wear, and make sure each person has the right size.

Fit problems are easy to overlook with borrowed or shared gear. Each person should be able to adjust and test their own items. A quick test is to ask each worker to put on their gear and move through the motions of the job. Gaps, pinch points, and slipping often show up in seconds, and adjustments can be made before real work begins.

Is it in good condition?

Cracked goggles, torn gloves, flattened ear plugs, and worn-out boots remain in use because replacing them is a hassle. Inspect before each use and replace damaged items promptly.

Follow the manufacturer's guidance on service life. Do not guess.

Some damage is hidden, such as a hairline crack in a lens or a slow leak in a seal. If something does not feel right, retire it and compare with a new one. Keep a simple check routine at the start of each shift: look, feel, and test. If anything seems off, replace it rather than hoping it will hold for one more day.

Is it being worn all the time?

Quick jobs, hot days, and habit lead to skipped gear. Many injuries happen during a task that was supposed to take a minute.

Keep gear within reach of where tasks begin, and build the habit of putting it on first.

Pressure from deadlines makes people skip steps. Leaders can help by planning time for gear into the schedule, so that using it is not seen as slowing down. Be honest about what makes gear hard to wear on your farm, whether heat, noise, dust, or awkward timing, and look for real solutions together.

• Put gear on before starting.
• Do not skip it for short jobs.
• Keep it where the task starts.

Is it put on and taken off correctly?

Contaminated gear can transfer residue to skin, face, and home. Learn the proper order and method for taking it off, and wash hands afterward. Hands-on training is the best way to learn this.

Do not wear contaminated gear in vehicles or living areas.

Taking gear off in the wrong order, or touching your face with a contaminated glove, is a classic problem. Practice with someone who can point it out.

Is it stored and cleaned properly?

Gear left in sun, heat, or chemical areas degrades. Follow maker's instructions for cleaning and storing, and keep gear for chemical work separate.

Clean regularly, and do not share items such as respirators.

Mixing up clean and contaminated gear in the same bin is another trap. Label bins and keep them apart. Gear that is stored in the cab of a truck, in direct sun, or near fuel can degrade quickly. A shaded, dry, labeled storage area makes gear last longer and be easier to find.

Are people trained and supported?

Handing out gear without explanation leads to many of these mistakes. Train people, check their use, and encourage questions. Confirm requirements with OSHA.

Review mistakes without blame, and fix what makes them likely.

Make it safe to say 'I did not know how to use this.' Workers who feel judged hide mistakes, while workers who feel supported ask for help, which is what you want. Short, regular check-ins, such as a two-minute talk at the start of the day, catch drift before it becomes habit.

Last reviewed: November 12, 2026. Written by the Farm Safety Editorial Team. See our editorial policy.