Personal Protective Equipment in the Workplace: What OSHA Requires

Key Takeaways

• OSHA PPE requirements under 29 CFR 1910 Subpart I and 1926 Subpart E define how employers must select, provide, and maintain personal protective equipment (PPE) to protect employees from identified hazards.
• PPE must align with task-specific risks across the six hazard categories defined by OSHA. These assessments guide the selection of types of PPE such as safety boots, face shields, and electrical protective equipment.
• Noncompliance often stems from poor fit, lack of enforcement, or resistance due to discomfort—addressing how PPE in the workplace is introduced and reinforced is key to behavior change.
• Employers must also consider performance standards from ANSI, ISO, ASTM, NFPA, CE, and NIOSH, which provide essential criteria for verifying the quality and reliability of all equipment worn.

What Is PPE?

PPE stands for Personal Protective Equipment, which refers to equipment worn by workers to reduce exposure to hazards that remain after all other safety measures have been applied. The Occupational Safety and Health Administration (OSHA) defines and enforces standards for PPE in the workplace across both general industry and construction settings. The goal is to minimize exposure to risks that could cause injuries, illnesses, or fatalities.

OSHA outlines PPE requirements under two main regulatory parts:

• General Industry (29 CFR 1910 Subpart I): Covers sectors like manufacturing, warehousing, and healthcare. Addresses protections such as eye protection, respiratory protection, and hand protection.
• Construction (29 CFR 1926 Subpart E): Focuses on construction PPE, including fall protection, head protection, and safety boots for job sites involving elevation, moving equipment, or structural hazards.

Employers must follow the applicable OSHA PPE standard based on the nature of the work being performed. Both subparts require hazard-specific assessments, proper types of PPE, and ongoing training and maintenance.

PPE is not the first solution—it's the last. OSHA uses a Hierarchy of Controls model to prioritize how to protect workers:

1. Eliminate the hazard entirely.
2. Substitute with something safer.
3. Apply Engineering Controls to isolate the hazard.
4. Use Administrative Controls, like job rotation or restricted access.
5. Provide PPE to reduce harm when other controls can’t fully remove the risk.

Why Should You Wear Personal Protective Equipment?

In 2023, private industry employers in the U.S. reported 2.6 million nonfatal workplace injuries and illnesses, with nearly 946,500 cases resulting in days away from work. These incidents lead to lost productivity, insurance costs, and operational delays, most of which could have been reduced through the proper use of PPE. This underscores the role of PPE in the workplace, not just as a compliance requirement, but as a direct contributor to workforce stability and cost control.

Importance of PPE

• Protects Employees from Immediate Harm: When engineering or administrative controls can’t eliminate a hazard, PPE is the last protective barrier. It shields workers from injuries caused by physical impact, exposure to chemicals, or high-decibel noise.
• Reduces Downtime and Injury-Related Costs: Proper use of PPE helps prevent incidents that would otherwise halt operations or require expensive interventions. This is especially critical in sectors where high-risk tasks are routine, such as construction or manufacturing.
• Supports Compliance with OSHA Standards: Adhering to the OSHA PPE standard reduces legal and financial exposure during inspections and audits. Failing to meet PPE requirements can lead to fines, work stoppages, or even litigation.

Limitations of PPE

• It Does Not Eliminate the Hazard: PPE reduces the severity of exposure but does not remove the danger itself. That’s why it should always follow higher-level controls in OSHA’s hierarchy.
• Improper Use Weakens Protection: If PPE is worn incorrectly, not maintained, or not matched to the hazard, its effectiveness drops significantly. This can mislead workers into thinking they’re protected when they’re not.
• Comfort and Usability Issues: Workers often resist using PPE that restricts movement, vision, or comfort. This leads to inconsistent usage, especially when construction PPE or protective clothing interferes with physical tasks.

The Six Different Categories of Hazards

To meet OSHA PPE requirements, employers must first identify the kinds of hazards present in each work environment. This is done through a formal hazard assessment, which determines the right types of PPE to protect employees. OSHA groups workplace hazards into six core categories, each requiring a different approach to protection.

1. Physical Hazards: These include objects or conditions that can cause physical harm, such as falling objects, sharp edges, extreme temperatures, noise, and vibration. Workers in the construction, manufacturing, and transportation industries are often exposed to physical hazards.
2. Chemical Hazards: These hazards are caused by exposure to harmful chemicals, such as gases, vapors, liquids, and solids. Workers in the chemical, pharmaceutical, and agricultural industries are at risk of exposure to chemical hazards.
3. Biological Hazards: These hazards arise from exposure to biological agents, such as viruses, bacteria, fungi, and parasites. Healthcare workers, laboratory technicians, and animal handlers are at risk of exposure to biological hazards.
4. Electrical Hazards: These hazards include the risk of electrocution or electric shock, which can be caused by exposed wiring, damaged electrical equipment, or contact with power lines. Workers in the electrical, construction, and maintenance industries are at risk of electrical hazards.
5. Mechanical Hazards: These hazards are caused by moving machinery or equipment, such as conveyors, forklifts, and heavy equipment. Workers in the manufacturing, construction, and transportation industries are at risk of mechanical hazards.
6. Radiological Hazards: These hazards arise from exposure to radiation, such as X-rays, gamma rays, and radioactive materials. Workers in the nuclear, healthcare, and laboratory industries are at risk of radiological hazards.

Employers must perform and document a hazard assessment under 29 CFR 1910.132(d) to identify risks and determine the required types of PPE. This assessment must match specific tasks with the right gear based on the kind of exposure involved. It is a legal obligation under the OSHA PPE standard, not just a workplace guideline.

Types of PPE and When They Are Required

OSHA’s requirements specify which protections are required based on the type of hazard present and the nature of exposure. That means employers must match PPE to specific tasks, not just general job roles.

Many workplaces include overlapping risks that demand different types of gear used together. A welder might need respiratory, face, and hand protection at once. In contrast, someone working near energized equipment may only require electrical-rated gloves and boots. Correct use depends on identifying the hazard, verifying its source, and applying the PPE standard that fits the exposure.

Head Protection

Head injuries often result from falling objects, contact with fixed structures, or accidental head strikes against equipment. OSHA requires the use of head protection under 29 CFR 1910.135 for general industry and 1926.100 for construction when there is any risk of impact or electrical contact. The type of helmet used must match the hazard identified in the workplace assessment.

Common head protection includes:

• Type I and Type II Hard Hats: Type I protects from vertical impact, while Type II provides both vertical and lateral protection. The distinction matters most in environments where materials can fall or strike from the side, such as scaffolding or confined work areas.
• Class G, E, and C Ratings: Class G (General) provides limited electrical protection. Class E (Electrical) offers high-voltage protection up to 20,000 volts, often required for construction PPE in energized areas. Class C offers no electrical protection but includes ventilation for hot conditions.

Helmets must be inspected regularly for cracks, dents, or UV damage. Modified or drilled helmets are not compliant under the OSHA PPE standard. Fit, suspension system integrity, and cleanliness all affect the level of protection provided.

Eye and Face Protection

OSHA requires protection for the eyes and face when workers are exposed to flying particles, molten metal, chemical splashes, acids, vapors, or harmful light radiation. These rules fall under 29 CFR 1910.133 for general industry and 1926.102 for construction. Both standards require PPE that meets ANSI Z87.1 specifications.

Common forms of protection include:

• Safety Glasses: Suitable for low-impact hazards such as airborne dust, wood chips, or minor debris. Side shields are required to protect from lateral entry.
• Goggles: Provide a sealed fit around the eyes, blocking liquid, dust, or vapor exposure. Often used in chemical handling, spray applications, or lab work.
• Face Shields: Used alongside eye protection, not as a replacement. Designed for high-risk tasks like grinding, cutting, or pouring corrosive materials where the full face is exposed.
• Welding Helmets and Filters: Required for arc welding, torch cutting, or other processes that produce intense light or sparks. Shading must match the intensity of the operation.

Cracked lenses, scratched visors, or missing straps reduce effectiveness and do not meet OSHA PPE requirements. Employers are responsible for providing and maintaining the correct gear for each task involving these exposures.

Respiratory Protection

When workers are exposed to harmful dust, fumes, vapors, or oxygen-deficient environments, OSHA requires respiratory protection under 29 CFR 1910.134. This includes both general industry and construction work where airborne contaminants exceed permissible exposure limits or where engineering controls are not feasible. Respirator use must follow a written program that includes medical evaluations, fit testing, and training.

Common types of respirators include:

• Filtering Facepiece Respirators (e.g., N95): Used in environments with non-oil-based particles, such as construction dust or infectious droplets. These are tight-fitting and require seal checks before each use.
• Elastomeric Half- and Full-Face Respirators: Reusable and designed for tasks involving gases, vapors, or higher concentrations of particulates. Filter or cartridge selection depends on the specific chemical or airborne hazard.
• Powered Air-Purifying Respirators (PAPRs): Often used in healthcare, industrial hygiene, or high-particulate environments. These provide airflow through a filter and are easier to wear for extended periods.
• Supplied-Air and SCBA Systems: Required in confined spaces or where airborne concentrations are immediately dangerous to life or health. These deliver clean air from a separate source and are classified as high-level protection.

Hearing Protection

OSHA requires hearing protection when workers are exposed to noise levels at or above an 8-hour time-weighted average of 90 dBA under 29 CFR 1910.95. In construction, while the regulation is less prescriptive, enforcement still aligns with general industry thresholds. Noise exposure is common in manufacturing, demolition, road work, and heavy equipment operations.

Common types of hearing protection devices are:

• Earplugs: Disposable or reusable, these fit directly in the ear canal and are best for consistent high-noise environments. Correct insertion is essential to achieve the rated protection.
• Earmuffs: Cover the entire ear and are easier to fit properly across a wide range of users. They’re often used in combination with other PPE, like helmets or face shields, in industrial settings.
• Electronic or Noise-Level Dependent Protection: Designed to allow communication while suppressing harmful peaks. Common in utility work or environments with intermittent high-volume noise.

Hearing protection must be selected based on actual noise measurements, not assumptions. Overprotection can interfere with communication or warning signals, while underprotection leaves workers at risk for permanent hearing loss.

Foot Protection

Foot injuries can result from falling objects, sharp materials, punctures, or contact with hazardous surfaces. Under 29 CFR 1910.136 and 1926.96, OSHA requires foot protection when these risks are present, especially in construction, warehousing, and fabrication work. Footwear must meet the performance criteria outlined in ASTM F2413 and be appropriate to the specific hazard.

Common protective footwear includes:

• Safety Boots with Toe Protection: Steel, alloy, or composite toe caps prevent crush injuries from dropped tools, equipment, or materials. These are standard in nearly all construction PPE applications.
• Metatarsal Guard Footwear: Protects the upper part of the foot in addition to the toes. Often used in foundries, welding operations, and environments where heavy items are handled manually.
• Slip-Resistant or Chemical-Resistant Soles: Required in wet, oily, or corrosive areas. These reduce the risk of falls and contact with harmful substances on work surfaces.
• Electrical Hazard (EH) Rated Boots: Used where live circuits or energized equipment are present. These boots are designed to insulate against open circuits up to a defined voltage.

Footwear must not be altered, and damaged boots must be replaced. Employers are responsible for meeting OSHA PPE requirements, including determining if specialty footwear must be provided or if it qualifies under employee-owned exceptions.

Hand Protection

Hand injuries are among the most common workplace incidents, often caused by cuts, burns, abrasions, chemical contact, or extreme temperatures. OSHA addresses this under 29 CFR 1910.138, requiring employers to select gloves based on the specific hazards workers’ hands are exposed to. In construction, manufacturing, and maintenance, gloves are often part of daily personal protective equipment.

Common types of hand protection include:

• Cut-Resistant Gloves: Made from materials like Kevlar or high-performance polyethylene, used in tasks involving blades, glass, or sharp metal edges. The cut level must match the risk rating of the task, from light handling to heavy fabrication.
• Chemical-Resistant Gloves: Typically made of nitrile, neoprene, or butyl rubber. Used in labs, cleaning operations, or chemical transfer areas where liquids can damage skin or be absorbed.
• Thermal and Electrical Gloves: Insulated for extreme heat or cold, or rubber-insulated for electrical work. These gloves must be rated and tested according to task-specific requirements, including electrical protective equipment standards.
• General-Purpose Work Gloves: Often used for material handling, landscaping, or low-risk tasks. These provide grip and abrasion resistance but are not suited for high-risk hazards.

Gloves must fit properly and be in good condition to meet OSHA PPE requirements. Damaged, poorly sized, or inappropriate gloves can increase the chance of injury instead of preventing it.

Electrical Protective Equipment

Electrical work introduces hazards that can’t be addressed with standard PPE. OSHA outlines requirements under 29 CFR 1910.137 for general industry and 1926.97 for construction, covering items used to insulate, shield, or isolate the body from energized conductors. This includes gloves, sleeves, blankets, line hoses, and other rubber-insulating equipment.

Key types of electrical protective equipment include:

• Rubber Insulating Gloves and Sleeves: Must be tested before first use and every 6 months thereafter. Class ratings (00 through 4) indicate maximum use voltage, ranging from 500 to 36,000 volts.
• Insulating Blankets, Line Hoses, and Covers: Used to isolate exposed parts of live equipment during maintenance or repair. These help prevent accidental contact in tight spaces or overhead work zones.
• Dielectric Footwear: Required in environments where workers are exposed to energized parts. These boots are part of both construction PPE and utility operations when step potential or electrical arc is a concern.

All insulating equipment must be visually inspected before use. Surface cracks, embedded foreign material, or chemical damage are grounds for immediate removal from service. OSHA also requires equipment to meet applicable ASTM standards and be stored to avoid distortion or contamination.

Fall Protection

Falls remain the leading cause of death in construction. In 2023, there were 421 fatal falls to a lower level out of 1,075 construction fatalities, according to BLS data. These incidents are preventable and highlight the importance of proper fall protection measures.

Under 29 CFR 1910.140 and 1926.104–106, OSHA includes certain fall protection systems—such as harnesses, lifelines, and safety nets—under Personal Protective Equipment (PPE). These apply when other controls are not possible and when a hazard assessment identifies fall risks that require body-worn protection.

While these sections address PPE-based solutions, they do not replace full fall protection planning found in other subparts like 1926 Subpart M or 1910 Subpart D.

Examples of PPE for fall protection include:

• Full-Body Harnesses: Must meet OSHA performance criteria and be worn with compatible connectors. Used to reduce injury during a fall by distributing force across the body.
• Lifelines and Lanyards: Connect the harness to an anchor point. These must meet minimum strength ratings and limit fall distance and arresting force.
• Safety Nets: Used in construction when personal fall arrest systems are not practical. Positioned close enough to catch a falling worker before impact becomes fatal.
• Personal Flotation Devices (PFDs): Required under 1926.106 when working over or near water. These are classified as PPE to prevent drowning during an unprotected fall.

Levels of PPE

Not all protective equipment offers the same degree of protection. Some tasks require full-body coverage with respiratory and chemical barriers, while others call for basic gear like gloves and safety boots. OSHA does not define formal PPE levels across all industries, but in practice, PPE is often grouped into tiers based on exposure severity, especially in hazardous material response, healthcare, and industrial settings.

Level A

The highest level of protection is required when the worker faces the most severe exposure risks, such as highly toxic chemicals or hazardous materials in vapor or gas form. Full encapsulating suits, self-contained breathing apparatus (SCBA), and gloves and boots with chemical resistance are part of Level A PPE.

Level B

This level offers protection against high respiratory risks but allows for a lesser degree of skin protection. Workers may wear non-encapsulating suits with SCBA or supplied air respirators, gloves, and boots. Level B is often used when there is a risk of chemical exposure through inhalation, but less risk of direct skin contact.

Level C

Level C protection is suitable for environments where airborne contaminants are present, but the risk to the skin is lower. This level typically involves the use of air-purifying respirators instead of SCBA, combined with splash-protective clothing, gloves, and boots.

Level D

Level D is the most basic form of protection and is often used in standard work environments where minimal risks are present. This level typically involves standard work uniforms or coveralls with protective footwear. Hard hats, gloves, and eye protection may be added based on the job.

Selection, Use, and Maintenance of PPE

Under 29 CFR 1910.132(d), employers must conduct a written hazard assessment to determine where Personal Protective Equipment (PPE) is necessary. But selecting the right gear isn't enough. It must also match the conditions of the job, fit the worker correctly, and remain reliable through consistent use.

A compliant program must address three key areas:

1. Task-specific selection

PPE must be chosen based on the exact exposure, not just the job title. For example, a worker handling corrosive chemicals may need different gloves depending on contact duration or concentration level.

2. Fit and accessibility

One-size-fits-all approaches fail. Proper fit affects comfort, wear time, and the gear’s ability to actually protect. As Abby Ferri, CSP, puts it:

"PPE fit should be communicated in a way that a worker can understand their size, and the employer must make the effort to purchase the sizes needed, no matter the quantity."

3. Ongoing maintenance and inspection

PPE must be kept in clean, usable condition. Cracked visors, stretched harnesses, or expired filters (like those shown in the image below) are compliance failures, not minor issues.

Poor selection or inconsistent upkeep turns PPE into a formality rather than protection. The OSHA PPE standard requires that every item be evaluated not just for presence, but for performance.

Employer Responsibilities Under OSHA PPE Requirements

OSHA does not leave the responsibility for PPE in the workplace open to interpretation. It places legal and financial accountability on the employer, not the worker. This includes failure to comply with PPE requirements, failure to train, and failure to pay for required equipment worn on the job.

Training and Certification

Training is required under 29 CFR 1910.132(f) for every employee who uses Personal Protective Equipment (PPE). OSHA mandates that workers must know when PPE is necessary, what types of PPE to use, how to wear it correctly, and how to care for it. This includes proper procedures for removing contaminated items and recognizing signs of wear that make equipment worn unsafe.

Certification of training must be documented. Employers are required to record the date of training, the specific PPE covered, and the names of employees trained. This record must be made available during inspections or in the event of an incident involving PPE failure.

Retraining is necessary if any of the following occurs:

• An employee uses PPE incorrectly or fails to follow safety procedures.
• A change in the workplace or process introduces new hazards.
• The type of required PPE in the workplace changes due to a revised hazard assessment.

Failure to meet the OSHA PPE requirements for training is a frequent citation during inspections. Certification proves the employer met their obligation to inform and protect.

Why Employers Must Pay for PPE

Under 29 CFR 1910.132(h), employers must provide Personal Protective Equipment (PPE) at no cost when it is required to protect workers from hazards. This includes items such as safety boots, face shields, gloves, chemical-resistant gear, and fall protection systems. The rule eliminates confusion around who pays and reinforces the employer’s full responsibility under the OSHA PPE standard.

The intent is to prevent safety from becoming a financial decision. If workers are left to purchase their own gear, they may delay replacement, choose inadequate products, or avoid using PPE altogether, raising the risk of injury.

In a notable enforcement case, OSHA issued a citation after an employer failed to pay for required foot protection and welding gloves. While the case was initially challenged, it prompted OSHA to issue formal rulemaking reinforcing that employers must cover the cost of all PPE required by the hazard assessment. Exceptions are limited and clearly defined, such as non-specialty safety boots or prescription eyewear used outside of work.

OSHA PPE requirements are not met by simply offering guidance. The employer is obligated to pay for, supply, and maintain the correct equipment worn for protection.

Other Regulations and Standards for PPE

While OSHA defines the legal baseline for PPE in the workplace, employers often rely on additional technical standards to guide design, performance, and testing. These organizations help refine the quality, consistency, and appropriateness of types of PPE used across industries.

ANSI (American National Standards Institute)

ANSI standards define performance requirements for equipment such as eye protection, hard hats, and high-visibility garments. These standards are frequently incorporated by OSHA and are used by safety professionals to evaluate whether PPE meets necessary impact resistance, visibility, or electrical protection thresholds.

CE Marking

CE Marking certifies that PPE sold in the European Economic Area complies with EU safety, health, and environmental regulations. Manufacturers must conduct conformity assessments, and employers sourcing PPE internationally often require CE-labeled products for compliance with regional standards and export requirements.

ISO (International Organization for Standardization)

ISO develops global standards across a wide range of PPE, from protective clothing to respiratory protection. These standards support international consistency, particularly in supply chains involving multi-country operations or global project specifications where OSHA rules may not apply directly.

NIOSH (National Institute for Occupational Safety and Health)

NIOSH certifies respiratory PPE and provides guidance for use in healthcare and high-risk work settings. In clinical environments, this includes proper access to gloves, gowns, masks, and face shields, along with annual retraining per CDC recommendations. Employers are expected to manage donning/doffing procedures, stock rotation, and storage conditions to maintain readiness and performance.

NFPA (National Fire Protection Association)

NFPA publishes standards for PPE used in fire services, rescue operations, and hazardous material response. These include thermal protection, flame resistance, and electrical protective equipment requirements critical for emergency response and utility work.

ASTM (ASTM International)

ASTM develops testing and performance specifications for gloves, foot protection, barrier materials, and chemical resistance. Many OSHA-recognized PPE items cite ASTM test methods on labeling or packaging, which helps verify their protective capabilities in real-world use.

These standards support regulatory compliance, but they also provide the technical benchmarks for sourcing, training, and evaluating the safety performance of all equipment worn by employees.

Why Workers Skip PPE (and How to Change That)

Access to PPE in the workplace doesn’t guarantee it gets used. Workers often skip it not because they forget, but because of how the work environment is structured—culturally, physically, and socially. Risk becomes background noise, and PPE becomes optional the moment wearing it slows the task down, signals inexperience, or adds discomfort with no immediate benefit.

What Drives PPE Avoidance?

• Risk Normalization: In repetitive, high-exposure environments, hazards become familiar. The absence of injury is read as proof that skipping PPE is fine, even if it never was.
• Production Pressure: When deadlines are tight, equipment worn for safety can be viewed as an obstacle. Workers often learn, implicitly, that speed is rewarded more than safety.
• Cultural Drift: In workplaces where PPE use is inconsistent or selectively enforced, workers take their cues from habits, not handbooks. Peer behavior quickly outweighs formal policy.

Why Traditional Training Doesn't Shift Behavior

Training usually focuses on rules and equipment use. But that rarely addresses how people actually make decisions in real-time. Telling someone when to wear gloves doesn’t matter if the gloves make it harder to do the job, no one else wears them, or the task is performed hundreds of times a day without incident.

This gap is not a knowledge issue but a behavioral one. Here’s what actually works:

• Change What’s Normal, Not Just What’s Allowed: Workers are more likely to wear PPE when it feels routine, not exceptional. Making gear part of the task layout—stored at point-of-use, included in daily prep—reduces friction and increases consistency.
• Use Behavioral Reinforcement, Not Just Correction: Spotting and reinforcing correct use on the floor—not just citing non-compliance—builds patterns faster. Supervisors who model PPE use and recognize it publicly shift norms without issuing constant reminders.
• Design Around Use, Not Just Hazard: PPE selected purely by hazard without considering task frequency, dexterity, and environment leads to rejection. Workers are far more likely to wear gear they helped evaluate or that suits how they actually move and perform.
• Address Peer Influence Directly: When newer workers see experienced teams skipping PPE, they adjust behavior immediately. Programs that succeed make example-setting a requirement, not a suggestion, for leads and foremen.

A worker skipping PPE isn’t the failure. The failure is when no one notices, no one says anything, or worse—when it’s expected. If a safety program tolerates that once, it teaches it every time after.

FAQs

Who is responsible for making sure that workers know how and when to use PPE?

The employer is responsible under the OSHA PPE standard for training workers on the proper use, timing, and limitations of personal protective equipment (PPE). This includes initial training, retraining, and keeping records to show that workers understand what’s required.

Who is responsible for making sure that PPE fits each worker properly?

Employers must provide PPE in the workplace that fits each individual correctly. Ill-fitting equipment worn compromises protection and does not meet OSHA PPE requirements.

What should you consider when choosing the type of full-body protection you use?

Selection depends on the hazard type, exposure level, duration, and required PPE levels. You must also consider heat stress, mobility, and protective clothing compatibility with other gear.

Which type of PPE clothing is best for hazards that can occur in any direction?

Full-body protective clothing that provides 360-degree coverage, such as chemically resistant suits or arc-rated coveralls, is best for unpredictable exposure. Look for PPE rated for full enclosure and directional impact resistance.

Which personal protective equipment can reduce the risk of pressure points?

Well-fitted safety boots, padded harnesses, and ergonomic head protection are all types of PPE designed to reduce pressure on contact points. Selection should prioritize comfort without compromising safety performance.

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