When Must Employees Wear PPE? Australia Workplace Guide (2025)

Snapshot: What you’ll learn

Personal protective equipment (PPE) is the last barrier between a worker and a hazard. This guide explains when it must be worn, who supplies it, and how to select and maintain it. It also breaks down requirements by industry, highlights recent 2025 considerations, and offers a practical checklist to stay compliant.

Who this guide helps

The information here applies to a wide range of people:

• Employers and Persons Conducting a Business or Undertaking (PCBUs)

• Health and safety representatives (HSRs)

• Supervisors and managers

• Workers in construction, trades, healthcare, hospitality, horticulture, warehousing, and workshops

• Contractors and site visitors who enter controlled work areas

PPE defined (and what isn’t PPE)

PPE includes any clothing or equipment designed to reduce injury or illness from hazards at work. This covers a wide range of items, from head protection such as hard hats and bump caps to eye and face protection like safety glasses, face shields, and welding helmets. Hearing protection includes earmuffs or earplugs, while respiratory protection ranges from disposable masks to powered respirators. Hand and arm protection can involve gloves resistant to cuts, heat, or chemicals. Foot protection may mean steel-capped boots or slip-resistant shoes. Body protection includes high-visibility vests, aprons, and protective coveralls. Fall-arrest systems such as harnesses and lanyards are also part of PPE.

Items not considered PPE include engineering controls such as machine guards, administrative controls like rotating shifts to reduce exposure, and general workplace amenities such as sunscreen at a site station.

Some uniforms overlap with PPE. Chef whites, for example, protect against burns and spills, making them PPE in kitchen environments.

Where PPE fits: Hierarchy of control

PPE is only one part of risk management. The hierarchy of control ranks safety measures from most effective to least effective:

1. Eliminate the hazard entirely

2. Substitute the hazard with something safer

3. Isolate the hazard from workers

4. Apply engineering controls to reduce exposure

5. Apply administrative controls to change the way work is done

6. Use PPE to protect workers from any remaining risk

Because PPE is the final defence, it should be paired with other measures such as guarding, ventilation, signage, and non-slip matting to address the hazard at its source.

When PPE is required

PPE is mandatory when a risk assessment identifies that other controls cannot remove or reduce a hazard to a safe level. A 2024 study of small and medium-sized enterprise workers found that only 64% used PPE correctly. The same study reported that 34% of workplace accidents happened when workers were not wearing PPE, and 13% occurred due to improper use.

It may be needed for impact or crush hazards from falling or moving objects, or when sharp tools or machinery create a risk of cuts. Contact with chemicals, infectious material, or hazardous dust also requires the use of PPE.

Prolonged noise exposure above safe limits is another trigger, as is work that generates fumes, smoke, or fine particles. Extreme temperatures, both hot and cold, can demand protective clothing. Electrical hazards, UV exposure from sunlight or welding arcs, and slippery or uneven surfaces are further situations where PPE is necessary.

Tasks performed at height or involving hot work such as welding or grinding also require PPE. Visitors and contractors must follow the same PPE standards as workers when entering hazardous areas.

Roles and responsibilities

While these responsibilities are clear in policy, real-world practices can differ. In a Reddit discussion among tradespeople, one worker commented, “A lot of people are ignorant to wearing PPE. They just don’t know… I’m one of the only people who regularly wears a respirator.” Another added, “Depends on the job... Usually the boss isn’t paying for the PPE so they would have to provide it themselves.” These views highlight that compliance often depends on awareness, training quality, and who bears the cost of equipment.

Selecting the right PPE

Selection starts with the hazard. Consider the task, exposure time, and environmental conditions. PPE must be fit for purpose, comfortable enough for prolonged wear, and available in suitable sizes.

Australian and New Zealand standards (AS/NZS) specify requirements for various PPE types, including helmets, hearing protection, eye protection, respirators, gloves, footwear, and fall-arrest systems.

Compatibility matters. Safety glasses must fit under a face shield, and respirator straps must not interfere with hard hat stability.

An inclusive approach is important. PPE should accommodate prescription glasses, head coverings, or facial hair, with suitable alternatives like powered air-purifying respirators (PAPRs) when needed.

Fit, testing, and wear

• Respirators: Fit testing is mandatory for tight-fitting types like P2 or N95 masks. Workers must perform a seal check every time they wear one. Beards can prevent a proper seal, so an alternative design may be needed.

• Hearing protection: Select protection based on the noise level. Avoid excessive attenuation, which can make communication unsafe.

• Footwear: Choose soles with appropriate slip resistance. For construction, add steel toe caps and penetration-resistant midsoles. Electrical work may require insulating properties.

• Garments: Match materials to hazards—arc-rated for electrical, flame-resistant for welding, chemical-splash-resistant for laboratory work. For visibility, select the correct high-vis class for day, night, or combined use.

• Fall-arrest gear: Inspect harnesses and lanyards before every use. Follow manufacturer inspection intervals for formal checks.

Using, cleaning, and storing PPE

PPE is only effective when it’s worn correctly and kept in good condition.

• Follow correct donning and doffing steps to avoid contamination.

• Clean PPE according to the manufacturer’s instructions—especially items contaminated with hazardous substances.

• Provide suitable storage away from direct sunlight, heat, or corrosive chemicals.

• Replace PPE immediately if damaged, expired, contaminated, or no longer fitting correctly.

Training, supervision, and records

Workers should be trained before PPE is issued. The training must include:

• Why the PPE is required

• How to fit and adjust it correctly

• How to check it for damage

• Correct cleaning and storage methods

• The limits of the protection it provides

Supervisors should observe PPE use during work. Spot checks help identify misuse or neglect. Records should be kept for:

• PPE issue dates

• Training completion

• Fit test results

• Inspection logs

• Replacement dates

These records help with audits and compliance checks from regulators.

Industry and task-based quick guides

Construction and civil

Workers should wear hard hats, high-visibility clothing, and steel-capped boots at all times on site. Additional PPE depends on the task:

• Safety glasses when cutting or grinding

• Hearing protection for noisy plant and machinery

• Respirators for dust or fumes

• Harnesses for working at height

Electrical

Electricians need arc-rated clothing, insulated gloves, and dielectric boots. Face shields protect from arc flashes. Work on live equipment should only be done with PPE rated to the correct standard. Insulated mats can reduce electrical shock risks.

Plumbing and HVAC

Common PPE includes cut-resistant gloves, safety glasses, and steel-capped boots. Respirators protect against dust, mould, and sewage aerosols. Knee pads reduce strain during floor-level work. Waterproof gloves prevent skin contact with harmful substances.

Workshops and manufacturing

Eye protection is a priority for grinding, drilling, or cutting. Hearing protection is needed near loud equipment. Steel-capped boots, cut-resistant gloves, and flame-resistant aprons protect from sparks, sharp edges, and heat. Welders should use welding helmets, gloves, and fire-retardant clothing.

Warehousing and logistics

High-visibility vests keep workers visible to forklift operators. Safety boots with toe protection reduce injury from falling goods. Anti-slip soles prevent falls in loading areas. Gloves protect from cuts when handling sharp packaging or pallets.

Horticulture and landscaping

Chainsaw use requires cut-resistant trousers, gloves, and face protection. Sun protection includes UPF-rated clothing, hats, and sunscreen. Chemical handling may require respirators and chemical-resistant gloves. Ear protection is recommended for prolonged power tool use.

Hospitality and food production

Kitchen staff benefit from non-slip shoes to reduce fall risk on wet floors. Heat-resistant gloves protect from ovens and hot trays. Cut-resistant gloves help prevent knife injuries. Protective aprons and chef whites reduce the risk of burns and spills.

Healthcare and laboratories

Gloves, protective eyewear, and surgical masks are standard. For infectious disease control, respirators, gowns, and face shields may be required. Sharps-resistant gloves or sleeves protect in high-risk wards. Fit testing for respirators is mandatory in high-exposure environments.

Cleaning and waste management

Workers should wear chemical-resistant gloves, splash-proof goggles, and in some cases respirators. Puncture-resistant footwear is useful in waste handling. Protective clothing prevents contact with cleaning agents or contaminated waste.

Slips, trips, and flooring controls (Matshop focus)

PPE footwear works best when paired with floor-level safety measures. In high-traffic or spill-prone areas, safety matting reduces slip incidents and adds comfort.

• Entrance mats trap dirt and moisture before it reaches work areas.

• Anti-fatigue mats help workers who stand for long periods by reducing strain.

• Wet-area mats drain water away from the surface to maintain grip.

• Non-slip runners add traction in corridors and production lines.

Placement should target entrances, kitchens, loading docks, and any space with frequent liquid spills. Regular cleaning keeps mat performance high. In our experience supplying safety mats to warehouses and kitchens, we’ve seen slip incidents drop immediately after installation, particularly in areas where PPE footwear alone wasn’t enough.

Quick compliance checklist

PPE Compliance Steps

1. Complete a risk assessment and document the findings.

2. Select PPE matched to each hazard and compliant with AS/NZS standards.

3. Fit test and train workers before issuing PPE.

4. Keep records of issue, inspections, and replacements.

5. Provide storage and cleaning facilities.

6. Replace PPE as soon as it shows signs of damage or wear.

7. Conduct regular audits to monitor usage and compliance.

Need the right PPE and safety matting for your workplace?

For slip and trip control, PPE is only part of the solution. The right safety matting works for every worker and visitor. Speak with a Matshop specialist about mats suited to your site. Call 1300 628 746 or use the online chat to get tailored recommendations.