Choosing the Right PPE: A Practical Guide for Victorian Employers
Personal protective equipment is often the last line of defence between a worker and a serious injury. Yet in many workplaces across Victoria, PPE is selected without a clear method, without reference to actual hazards or without understanding what the OHS Act requires. During inspections it is common to see PPE that appears compliant but provides very little real protection. The intention is right but the outcome is not.
This guide explains how employers can choose the right PPE using a risk-based approach that aligns with the OHS Act 2004 and WorkSafe Victoria expectations. It also helps decision makers understand how PPE fits into the broader system of risk control and where independent advice can strengthen compliance and reduce risk.
1. Start with the hazard. PPE is not the starting point.
Under the OHS Act, employers must eliminate or reduce risks so far as is reasonably practicable. PPE sits at the lowest level of controls because it protects the individual, not the hazard.
A practical PPE assessment always begins with:
what is the hazard
what is the exposure
what are the consequences
PPE is only used when higher level controls are not possible or do not fully control the risk. This is the expectation during an inspection and it is the standard employers are judged against.
2. Understand what the OHS Act 2004 requires from employers
The Act requires employers to:
provide suitable PPE
ensure the PPE is maintained, repaired or replaced as needed
ensure workers are instructed and trained in its use
ensure PPE does not introduce additional risks
consult with workers when selecting PPE
Many non-compliances arise because PPE is assumed to be the simple part. In practice, it requires the same level of justification and documentation as any other control measure.
3. Select PPE using a clear method based on risk
Choosing PPE should never be based on catalogue descriptions or supplier claims alone. A defensible approach covers the following.
Fit for the hazard
Respiratory protection that is not suited to the particulate size, glove material that reacts with chemicals, eye protection that is the wrong rating or hearing protection that does not reduce exposure adequately are common findings during inspections.
Fit for the worker
PPE must be practical and usable. If it does not fit, workers will modify or remove it. This is a predictable behavioural risk that employers must anticipate.
Compatibility
Multiple PPE types must work together. For example, respiratory protection and eye protection often conflict.
AS/NZS standards
Ensure products are certified to the correct standard. Not all PPE sold in Australia meets the relevant AS/NZS requirements. This is more common than many employers expect.
Verification
Request evidence from suppliers. Ask for test reports, certification or product conformance documents.
4. Build a simple PPE procedure that workers can follow
A strong PPE system includes:
when PPE must be used
who is responsible for issuing it
how wear and tear will be monitored
replacement triggers
fit testing where required
cleaning and storage requirements
Training must be practical. Workers need to know how to don and remove PPE correctly, how to maintain it and what to report.
Include a PPE Matrix
A PPE Matrix is a simple table that sets out:
the task or activity
the hazard
the PPE required
the AS/NZS standard to reference
replacement frequency
any compatibility notes
This gives workers one clear reference point and removes ambiguity. It also provides employers with a defensible document to demonstrate that PPE selection is linked to risk and task requirements, not guesswork. In inspections, a well built PPE Matrix helps show that PPE has been selected systematically and reviewed through consultation.
5. Common PPE failures seen during inspections
Across manufacturing, warehousing, construction, healthcare and community settings, the same issues appear repeatedly:
PPE does not match the actual hazard
respiratory protection used without fit testing
gloves unsuitable for the chemicals present
PPE purchased based on price rather than performance
no documented replacement schedule
workers unclear on when PPE is required
old stock still being issued
These failures are preventable when PPE selection is built on risk, evidence and consultation.
6. PPE for high risk tasks. Examples from Victorian workplaces
Welding
Workers often rely on incorrect gloves, unsuitable eye protection or clothing that does not meet heat or flame resistance requirements.
Chemical handling
Gloves degrade quickly if they are not matched to chemical type. The SDS will specify glove material. This is rarely checked in practice.
Dusts and airborne particles
Respiratory protection must be selected against the particle size and task. P2 is not always sufficient.
Noise
Hearing protection must reduce exposure below required limits but not by too much. Overprotection reduces situational awareness and can create other safety issues.
Task-based PPE selection is where many employers benefit from independent review because incorrect PPE is not always obvious until an incident or audit raises questions.
7. How PPE fits into a defensible safety system
PPE controls must link back to:
the risk assessment
the hierarchy of control
documented instruction
consultation
periodic review
This is what forms a defensible position if WorkSafe makes inquiries following an incident or complaint. PPE alone is never viewed as a complete control.
8. How RAS-OHS can support employers
RAS-OHS provides independent advice on selecting PPE that is actually fit for purpose and aligned with the OHS Act and current WorkSafe expectations. This includes PPE reviews, audit preparation, task-based assessments and development of simple, practical PPE procedures.
Over time RAS-OHS will integrate pre-qualified PPE solutions and bundles that meet AS/NZS requirements so businesses can make informed choices with confidence. The focus remains risk-based and practical, with an emphasis on systems that protect workers and stand up during inspections.
If support is needed to review a PPE system or develop a defensible PPE procedure, RAS-OHS is available to assist.
