Personal Protective Equipment (PPE) is an indispensable shield that keeps workers safe from a myriad of hazards—be it chemical exposure, falling debris, or infectious diseases. But while PPE equipment is designed to protect, it can also inadvertently introduce ergonomic risks.

In this article, we’ll explore the complex relationship between PPE and ergonomics, provide examples of how protective equipment can become an ergonomics hazard, and share practical strategies to minimize these risks.

What is PPE?

PPE refers to wearable gear that minimizes exposure to hazards that cause serious workplace injuries and illnesses. This can include:

• Respiratory protective equipment (RPE)
• Gloves
• Safety helmets
• Protective eyewear
• High-visibility clothing
• Safety footwear

The role of PPE in risk reduction is well established. Read more about PPE and RPE best practices here.

How PPE Creates Ergonomics Risk Factors

Despite its benefits, PPE can hinder natural movement and add physical strain. As illustrated in research published in the Journal of Occupational and Environmental Hygiene, PPE introduces ergonomic, human factor, and performance detriments in occupational settings. 

Over time, these factors can contribute to discomfort, fatigue, and musculoskeletal injuries.

Let’s look at some examples of ergonomics hazards caused by PPE.

Restricted Mobility

The most immediate ergonomics concern regarding PPE is that it might limit the body’s ability to move precisely, quickly, or with force.

Bulky protective suits or harnesses are particularly notorious for hampering the normal physical abilities of the wearer. For example, protective gear worn by firefighters is proven to limit range of movement and, therefore, inhibit dynamic task performance.1

Similarly, body armour systems worn by soldiers impede natural movement, potentially limiting performance in critical scenarios.2

Excessive Weight 

Heavy respirators or protective gear may be essential elements of high risk operations, but they introduce their own dangers.

Over time, excessive weight overloads muscles and joints, leading to ergonomic injury – potentially in a critical situation that requires full bodily autonomy to complete to a safe and satisfactory degree.

Reduced Hand Dexterity

Gloves are one of the most commonly used forms of PPE. While essential, gloves can impede fine motor skills, increasing strain during repetitive tasks or preventing the completion of tasks altogether.

Heat Stress

Protective clothing often traps heat and moisture, contributing to fatigue and dehydration. PPE that adds a lot of weight to the overall load, such as respirators, can also cause a quick and sustained rise in body temperature, particularly in high-stress situations that require a lot of movement.

Not only can PPE-based heat stress lead to physical injury – research shows that it can impair cognitive ability during the task, limiting outcomes and placing those involved at greater risk.3,4 

Poor Fit

Ill-fitting PPE increases pressure points and forces compensatory postures that strain the body. If too large, certain PPE items can also pose a snag or trip hazard, which can lead to serious harm, especially if the task involves working at height or other high risk scenarios.

In medical settings, it’s not just the PPE wearer at risk, but their patients as well. A study on the impact of ill-fitting surgical gloves revealed that even as little as one size too large or small reduced manual dexterity and put unnecessary pressure on the joints of healthcare workers.5

Analysis of poor fitting PPC also brings to light a disparity in consideration of male and female body types – with female workers often having to make do with protective equipment designed for men.

For example, a 2016 study found that some female firefighters wore turnout gear larger than the recommended size to accommodate their wider hips compared to their male colleagues. This resulted in reduced mobility and stunted performance – significantly increasing the risks involved with their role.6

This stems from roles requiring the use of PPE being disproportionately undertaken by male workers, but as we progress towards a more diverse workforce, female bodies must factor into early-stage design and sizing.

Strategies to Mitigate Ergonomic Risks of PPE

Considering the risks discussed above, it’s clear that ergonomic evaluations of PPE should be included in any effective risk management plan. 

While it’s true that fully eliminating the ergonomic risks associated with PPE requires changes from manufacturers and designers, there are still steps you can take to reduce PPE-related hazards and keep your team safe.

1. 1. Prioritize Fit and Adjustability – Ensure PPE is properly sized and adjustable for each worker. Every body is different, so for risky roles and tasks, PPE needs to be specifically suited to the wearer. There is rarely an effective one-size-fits-all solution to PPE.
   2. Rotate Tasks and Encourage Microbreaks – Limit the duration workers spend in restrictive, heavy, or hot equipment by rotating tasks and scheduling breaks for recovery.
   3. Provide Training – Educate employees on donning and doffing PPE correctly, as well as recognizing early signs of ergonomic injury. When using heavy PPE, individuals may need to train and maintain their fitness to safely carry these loads for longer durations.
   4. Choose Ergonomically Designed PPE – Where possible, look for products engineered to balance protection with comfort — lightweight materials, breathable fabrics, and ergonomically contoured designs.
   5. Conduct Regular Ergonomics Risk Assessments – Continuously evaluate the work environment and PPE to adapt strategies as risks evolve.

A comprehensive ergonomics risk assessment from Cardinus can help identify these hazards before they lead to injury. We offer in person, virtual, and telephonic ergonomics assessments to help you manage risk in a manner that’s most convenient for you.

Protect PPE Users with Cardinus

PPE remains a cornerstone of workplace safety. However, without proactive attention to ergonomics, the very equipment that protects workers can become a hidden source of harm.

By understanding these risks and implementing targeted strategies, organizations can ensure their employees are safe, comfortable, and able to perform at their best.

If you’d like help assessing or improving your ergonomics program, explore our end-to-end industrial ergonomics software, Healthy Working Pro – or contact Cardinus today.

Citations

1. McQuerry, M. Effect of structural turnout suit fit on female versus male firefighter range of motion. Applied Ergonomics, vol. 82, 2020, p. 102974.
2. Mitchell, K. B. Standard methodology for assessment of range of motion while wearing body armor. Army Natick Soldier Research Development and Engineering Center, 2013.
3. AlGhamri, A. A., Murray, S. L., and Samaranayake, V. The effects of wearing respirators on human fine motor, visual, and cognitive performance. Ergonomics, vol. 56, no. 5, 2013, pp. 791–802.
4. Hancock, P. Specifying and mitigating thermal stress effects on cognition during personal protective equipment use. Human Factors, vol. 62, no. 5, 2020, pp. 697–703.
5. Drabek, T., Boucek, C. D., and Buffington, C. W. Wearing the wrong size latex surgical gloves impairs manual dexterity. Journal of Occupational and Environmental Hygiene, vol. 7, no. 3, 2010, pp. 152–155. doi:10.1080/15459620903481660
6. Park, J., and Langseth-Schmidt, K. Anthropometric fit evaluation of firefighters’ uniform pants: A sex comparison. International Journal of Industrial Ergonomics, vol. 56, 2016, pp. 1–8.