Safety from head to toe

Keeping workers cool. Protecting their heads from traumatic brain injuries. Ensuring their eyes are adequately shielded from flying debris. Offering them comfortable yet protective gear.

These are only a few of the issues personal protective equipment manufacturers address to keep workers safe in a changing landscape.

Safety+Health spoke with leading PPE manufacturers on the ways these issues are affecting workers – from head to toe – and how employers can help. Here’s what they had to say.

Head protection

Proper head protection compliance is a leading issue the industry faces today, despite the fact that construction is widely considered one of the most dangerous professions out there. In the United States alone, the construction industry has the highest number of fatal and nonfatal workplace-related traumatic brain injuries out of any other industry. From 2003 to 2010, it represented 24% of all workplace-related TBI fatalities, according to the Centers for Disease Control and Prevention. Despite this, a recent survey from PPE provider J. J. Keller & Associates shows that a huge portion of construction workers aren’t wearing proper head protection on the job, with respondents reporting they simply don’t want to wear it (72%) or that they don’t think that it’s mandatory (50%). The survey results make it clear: The industry has an education problem. The threat TBIs pose aren’t being clearly articulated – and neither are the measures that can be taken to minimize risks. Although safety leaders have made substantial investments to educate the construction industry about best practices for head protection, much still needs to be done to increase head protection compliance.

– Joe Brandel, Business Development Manager for North America Industrial Safety Market, Mips

 

Eye/face protection

Eye and face protection is as vital as ever for professionals in the skilled trades. In 2020, there were more than 18,000 eye injuries in American workplaces, according to data from the Bureau of Labor Statistics. Construction workers accounted for more than 2,000 of them – the highest incident rate among all industries. These injuries, caused by hazards such as debris, corrosive substances and flying objects, not only harm workers but also lead to decreased productivity due to time off work. Addressing this issue requires understanding the specific hazards present on the jobsite and selecting protective equipment that meets these needs. Effective eye and face protection should offer a secure and comfortable fit, allowing for clear vision and unrestricted movement. It should also be durable enough to withstand harsh jobsite conditions while integrating seamlessly with other PPE, such as helmets or headlamps. Innovation in modular protective systems offers a promising solution. These systems allow workers to customize their protective gear, ensuring they’re adequately equipped for various jobsite demands. By providing superior protection and streamlining the process of equipping and reconfiguring safety gear, these solutions enhance both safety and productivity, working to reduce the risk of injury and allow workers to focus on the job at hand.

– Kyle Anderson, Senior Product Marketing Manager, Milwaukee Tool

 

In modern manufacturing, employee safety is crucial, particularly when it comes to eye protection. Despite its importance, getting employees to consistently wear PPE remains a challenge due to a number of barriers. A primary barrier is fit. Ill-fitting eyewear can cause discomfort and distraction, leading to noncompliance. Employers should provide a range of sizes and styles tailored to individual needs to enhance comfort and encourage use. Fogging lenses are another significant barrier, impairing visibility and causing frustration. Many of today’s safety eyewear come with anti-fog technology to ensure clear vision, reinforcing the necessity of eye protection while improving productivity. Clarity of lenses is also critical; distorted or scratched lenses increase the risk of incidents. High-quality eyewear that offers optimal clarity should be prioritized to enhance safety. Another factor is the overall aesthetic appeal of eye protection. Stylish designs can foster a positive attitude toward PPE. Lastly – and this is a big one – comfort is key. Lightweight, ergonomic designs help workers focus on their tasks. By addressing these challenges, organizations can promote a culture of safety that protects workers and boosts overall productivity.

– Nick Collins, NAM Trade Marketing Manager, Bollé Safety

 

Hearing protection

From our 45-plus years of experience, we’ve recently witnessed more companies considering the inclusion of fit testing in addition to their required audiometric evaluations, but – in several cases – only with new hires and those who may have demonstrated a threshold shift. This may be due to the time and expense to conduct such testing on all employees. Currently, fit testing for hearing protection is not a mandatory requirement by OSHA. Many employers reported that one of the biggest values of fit testing was educating employees on the proper use of hearing protection, in addition to minimizing the risk of overprotection.

– Garry G. Gordon, Audiologist, E.A.R. Inc.

 

Hand/arm protection

The biggest challenge that workers face today is comfort and, in turn, compliance. No one wants to wear uncomfortable safety garments. Workers will generally pull sleeves down to their forearms or ignore thumb slots and pull them up to prevent itchiness, excess compression or extra layers causing heat stress. Finding a solution can be complicated, as we’re obviously not a one-size-fits-all population. Using the proper materials and newest technologies is paramount to continue innovation and drive compliance, which is a major factor in keeping workers safe. New 21-gauge materials are ideal for ticking many of these boxes, and they’re available for an increasing number of applications as they come out in higher cut levels for garments and with a variety of palm coatings for gloves. For gloves, this means high cut resistance in softer gloves with better dexterity and high tactile sensitivity. For arm protection, these materials can be coupled with new bicep constructions for sleeves that provide lightweight, breathable protection that won’t fall down – even on very small or very large arms. And lighter materials are, in turn, thinner and cooler, which solves yet another increasingly common problem: workers overheating.

– Jason M. Lee, Manager, Health and Safety Services, Magid

 

Comfort and dexterity while maintaining protection levels continue to be the primary concerns for workers when it comes to hand/arm protection or any other PPE. With advancements in manufacturing techniques and machinery, the requirement for protection only increases. It’s important to ensure that, while developing technologies that provide higher mechanical protection from cuts, abrasions, etc., we also develop them to be more comfortable and dexterous to enable the workers to do their job, rather than it be an obstacle they have to overcome. PPE sizing is another important factor in achieving comfort and key in determining its wearability. If the gloves are too small, they can restrict movement, which discourages workers from wearing them. Similarly, loose gloves can bunch up or slip off at the slightest movement, making handling tasks very difficult. In either case, it exposes the wearer to risk of serious injuries. At the end of the day, comfort drives compliance. No matter how much protection the PPE is providing, if it interferes with the workers’ ability to do their job at a reasonable pace, they will not use it.

– Superior Glove

 

Respiratory protection

One of the biggest challenges an employer faces within a written respiratory program is making sure you can get everyone properly fit-tested. It’s important to understand what OSHA’s requirements are for when a fit test needs to be performed: initially and annually; if there’s any change in size, style, model or make of respirator; and if facial features change (weight gain/loss, dentures, facial scars, etc.). There are many factors to consider when selecting the proper mask size. Aspects such as facial shape, head size and body type all come into play. An example of a properly fit half mask would touch the bridge of the wearer’s nose at the top of the cup, cover the crease of their lips and fit firmly under their chin. There are two main types of materials used in air-purifying respirator masks: thermoplastic elastomer and silicone. TPE is a stiffer, more rigid material that doesn’t form to the face as well. Silicone is softer and more pliable, which will allow for a better fit to the face, more comfort and a greater likelihood of a successful fit test. Design can come into play if you’ve exhausted all efforts with sizing and material types. Many manufacturers will have mask options that will be a little wider set or offer a double or triple flange that will create more contact area and a better seal to improve the chances of a successful fit test.

– Andy Morgan, National Respiratory Sales Manager, Honeywell

 

Protective clothing

Ensuring thermal comfort and preventing heat stress in workers is paramount, especially in today’s changing climate. Workwear can play a vital role in regulating body temperature, and we see this as a growing area of importance. We’re working on the use of advanced textiles, such as smart fabrics, that will offer superior moisture management and breathability for the wearer. Proper garment design, considering mobility and fit, is crucial for overall comfort and safety. By understanding these factors, employers can select workwear that effectively supports thermoregulation and protects workers from heat-related illnesses.

– Kerry Jones, Senior Product Designer, Portwest

 

Foot protection

One of the biggest issues we’re seeing today when it comes to foot protection is a lack of proper preparedness on the job. With the rise of manufacturing, warehousing and distribution jobs in the United States, there’s a workforce entering the field that may be unfamiliar with the safety requirements of their jobs or uneducated as to what PPE might be available. This could be their first working environment that requires PPE, so they may be inclined to turn to the comfort, style and familiarity of casual sneakers rather than footwear that has been designed for safety and performance. Safety footwear is often associated with bulky and heavy work boots, but the reality of the current landscape is a demand for faster and lightweight footwear. As a result, we’re seeing footwear with athletic-inspired and trend-driven silhouettes that may resemble everyday footwear but still feature the performance and safety enhancements needed for the job. Before purchasing PPE, workers should understand the unique hazards of their job along with requirements from their company and regulatory bodies such as OSHA. Safety managers and supervisors are always a great starting point to learn more about what PPE is required for the job.

– Kevin Oberle, Senior Director of Global Insights & Engagement, KEEN Utility

 

One of the biggest foot protection-related issues facing workers today is the use of improper or inadequate footwear on the job. Many workers continue to wear shoes that don’t fit properly, which can lead to discomfort, fatigue and even long-term injuries. As feet can change over time, ensuring an accurate fit is crucial not only for comfort but also overall safety. We’ve observed that many trade workers request one size but are actually better suited for another. This mismatch can be due to various factors, including changes in foot shape and size, emphasizing the importance of proper fit in preventing foot-related issues. Additionally, wearing footwear that isn’t designed for specific job functions or environments poses a significant risk. Whether it’s the lack of slip resistance, puncture protection or insulation, the absence of the right safety features can lead to serious injuries. By prioritizing proper fit and understanding the necessary safety features for specific job roles, we can significantly reduce foot-related injuries and keep workers supported, comfortable and safe – all day, every day.

– Tito Warren, President of Global Industrial Sales and Operations, Red Wing Shoes

 

The biggest foot protection-related issue facing workers today is motivation – getting them genuinely excited about wearing safety footwear. It’s not just about meeting regulations; it’s about ensuring both younger and seasoned workers see their footwear as a key part of their work wardrobe. Modern safety footwear now offers comfort, protection and style, yet many workers are unaware of these options. The challenge lies in shifting perceptions – making safety shoes something workers are proud to wear daily because they’re comfortable, stylish and integral to their identity on the job. It’s also important to make safety leaders aware of modern options so they can champion these styles within their organizations, ensuring workers are equipped with footwear they are proud to wear. By bringing the “cool factor” into the workplace, we can change how safety footwear is perceived and adopted.

– Sam Sproull, Brand Marketing Manager, Warson Brands