PPE Risk Assessment, in Plain English

PPE sits right at the bottom of the hierarchy of control for a reason: it protects the person wearing it, but it doesn't remove the hazard itself. That's exactly why a PPE risk assessment gets misunderstood so often. It's not really an assessment of the PPE, it's an assessment of the task, that happens to conclude PPE is needed because nothing higher up the hierarchy removed the risk.

Here's how to do it properly, without the jargon.

PPE is the last resort, not the first thought

Before you get anywhere near deciding what PPE is needed, the question has to be whether the hazard can be removed or reduced another way. Can the task be done differently so the risk isn't there at all? Can the hazard be enclosed or guarded? Can the way people work be changed to reduce exposure? Only once those options are genuinely considered and ruled out (or used alongside PPE, not instead of it) does PPE selection actually start. A risk assessment that jumps straight to "provide gloves and goggles" without recording that this thinking happened is missing its most important part.

Match the PPE to the actual hazard, not a general category

"Wear appropriate PPE" isn't specific enough to be useful. Different hazards need different protection, and getting it wrong can be as bad as wearing nothing:

  • Eye protection: safety glasses for general risk of flying particles, or a full face shield for higher energy impacts or chemical splash
  • Hand protection: cut resistant gloves for sharp materials, chemical resistant gloves rated for the specific substance in use, not just "gloves"
  • Respiratory protection: the right filter type and rating for the actual contaminant, general dust masks don't protect against fumes or vapours
  • Hearing protection: rated for the actual noise level measured on site, not just handed out because machinery is nearby

A proper assessment names the specific hazard and the specific PPE rated to deal with it, ideally referencing the relevant standard (the CE or UKCA marking, and the EN standard number where it applies).

Fit and compatibility matter as much as selection

PPE that doesn't fit properly often doesn't protect properly, and this is a commonly missed part of the assessment. Respiratory protection needs a face fit test for tight fitting masks. Gloves that are too loose reduce dexterity and increase the chance of them being taken off. Where multiple items of PPE are worn together (a hard hat with hearing protection and eye protection, for instance) it's worth checking they're actually compatible and don't interfere with each other's seal or fit.

Training and maintenance, not just provision

Handing someone a respirator without showing them how to fit, check, and store it properly isn't meeting the legal duty. The assessment should record what training is given, how PPE is inspected before use, and how it's replaced when it's damaged or reaches the end of its working life. This is especially important for anything with a filter or cartridge that degrades over time.

Common mistakes in PPE risk assessments

The same few issues come up repeatedly: PPE listed as the only control with no mention of higher level measures considered first, generic terms like "suitable gloves" instead of naming the specific type and standard, no record of fit testing where it's needed, and no plan for replacement or maintenance. Any of these can turn what looks like a complete assessment into one that wouldn't hold up if something went wrong and got looked at closely.

Keep it specific to the job

The most useful PPE risk assessments read like they were written by someone who has actually seen the task being done, because they name the exact hazard, the exact PPE, and the exact standard it needs to meet. A generic PPE policy copied across every task on site is easy to write and much less useful to the people actually relying on it.

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