MRO Today asked some experts for tips on what makes PPE comfortable, from head to toe.

Hard hats
“The two keys in hard hat comfort are weight and adjustability,” says Alicia Socker, of ERB Safety, Woodstock, Ga.

Obviously, the lighter the hat, the more comfortable it will be, but adjustability may be more important.  Different types of suspension materials and how the hat adjusts determines how easily the hat can be customized to fit the worker’s head.

In addition to adjustment, Socker encourages employers to think beyond cost. 

“Often, a small factor like a full brim to keep off the sun or a ratcheting knob to quickly tighten the hard hat in windy conditions will increase worker compliance and safety.”

In addition to adjustment, Tim Swift of American Allsafe Company in Tonawanda, N.Y., recommends looking beyond the protection the hard hat offers. 

“Look at what the employee is doing,” says Swift.  “If the worker is on a ladder all day, a shorter brim on the hard hat allows him or her to see more easily.  On the other hand, workers in the sun may appreciate a longer brim.” 

Hearing protection
Surprisingly, something as simple as hearing protection often causes the most complaints among workers, says Michael Tesmer, Certified Safety Professional and technical support specialist with Conney Safety Products in Madison, Wis. 

“Although hearing protection is cheap and easy, many have a hard time becoming accustomed to the unusual feel of earplugs,” Tesmer says. 

In response, manufacturers have created a variety of ear plug styles to increase comfort and decrease cost, including disposable, corded and low-pressure foam models.

For those who just can’t stand the feel of earplugs, they can use muffs that completely cover the ears.  While muffs tend to be more comfortable in the short term, some users may complain about the pressure muffs exert on the head.  Adjustability is the key to comfort, Tesmer adds.

Eye protection
Safeguarding vision is one area where no one wants to compromise, and PPE suppliers offer a variety of eye protection products that can do the job.

The danger presented typically determines the style of protection needed.  Glasses are commonly used to protect from impact, while goggles offer more protection from flying objects and splashing liquids.

Swift agrees that fashion is important, but so are adjustability and complete coverage.  “Some of our models also come with a fog-resistant coating that can actually increase productivity and safety because workers don’t need to remove the glasses to eliminate the fogging," he says.

Using goggles often involves a tradeoff between protection and usability.  Because goggles cover the eyes more completely than glasses, they provide more eye protection, but can also be more susceptible to fogging.  Goggles with vents provide more complete protection against impact from solid objects than glasses, but the ventilation holes make them unsuitable in areas where chemical splashes or irritating fumes are a concern.  Goggles with indirect venting or sealed goggles are more likely to fog, reducing user comfort and safety.  Purchasing goggles with an anti-fog coating is essential, and Tesmer recommends that if fogging is a severe problem, a full-face respirator may improve user safety and comfort.

Body protection
Suits and overalls designed to shield the body range from $5 disposable overalls to a $3,500 “moon suit” designed to protect the entire body from the most hazardous environment.  Finding the right suit for the job means protecting against the exposure and ensuring comfort.

Protecting clothing from everyday dirt and workplace grime is no problem, says Mike Willis at Capler Protective Apparel and Fabrics, Guntersville, Ala.  He says in this instance, inexpensive non-woven synthetics can do the job.  But when the overall has to protect against liquids as well as dirt, comfort becomes more of an issue. 

“Because these suits can’t allow liquids to pass, they tend to hold in body heat and moisture as well keeping contaminants out.  You might as well seal them up in a baggie,” says Willis.

To counteract these drawbacks, Capler and other companies have developed fabrics that allow moisture to pass through but provide a seal to liquids, much like the well-known Gore-Tex brand fabric, but at a lower cost.

To also increase comfort, Willis recommends finding protective clothing that fits appropriately.  “As you cover more of the body, you restrict movement," he says.  " In these cases, range of motion becomes crucial.  Pick garments that fit the job as well as the body.”

Respirators
Because of the severe risk to workers from hazardous fumes, respirators are the only piece of PPE that requires fit testing.  OSHA standards for respirator use are strict, requiring training, worker evaluation as well as annual fit testing and documenting, or any time a worker’s facial characteristics change.  Workers should perform a personal positive and negative pressure check each time they don their respirators.  Depending on the hazard, federal regulations may also require qualitative testing, using an irritant smoke or odorous vapor to ensure a proper fit.

Respirator comfort is largely a matter of the respirator material, says Tesmer.  “Silicon rubber face masks offer the best comfort because of their pliability and softness, and their ability to spring back from deformation,” he says.

However, silicon is also the most expensive mask material.  Less-expensive options include plastic, which provides a comfortable seal but can become easily deformed and rubber, which is become less common because of increasing concerns with latex allergies.

Gloves
The danger in the workplace determines the type of gloves required and some gloves are naturally more comfortable than others.  Gloves designed to protect from chemical hazards must be impermeable, which reduces their comfort, while gloves designed to protect from abrasion can be made from breathable leather.  The material chosen and the fit of the glove determine its wearability.

For impermeable gloves, natural rubber has always been the material of choice, says Fred Seebode of North Safety Products, Charleston, S.C. 

“Natural rubber can be made very soft and dexterous, giving it a comfort that man-made materials can’t match,” he says.

Natural rubber is also less expensive than many synthetic polymers.

The concern about latex allergies is driving more manufacturers to offer synthetic gloves. 

“While synthetics can be manufactured to provide softness, chemical resistance or abrasion resistance, they can’t have all three simultaneously,” says Seebode.

Hands vary tremendously in size, and manufacturers offer a wide variety sizes and styles designed to fit different size hands and even different populations.