Is uncomfortable PPE putting compliance at risk?

David Ward, Technical Development Manager at Alsico, explains why improving comfort, communication and worker engagement could be key to closing the gap between PPE policy and practice.

Protective clothing has never been more technically advanced, yet many organisations are still facing the same challenge: ensuring workers wear their PPE correctly and consistently throughout their shift.

For years, conversations around PPE compliance have centred on awareness of risk. Today, however, the issue is often less about whether workers understand the hazards that exist and more about whether the clothing they are expected to wear is suited to changing working environments, from extreme climates to operational demands.

Ultimately, the gap between policy and practice remains one of the biggest barriers to improving workplace safety.

Risk assessments may identify the correct level of protection, procurement teams may specify garments with the right certifications, and policies may clearly outline what should be worn, but once that PPE reaches the workforce, the reality can look very different. Garments that are too heavy, poorly fitting or uncomfortable in warm conditions are more likely to be worn incorrectly, partially removed or adjusted in ways that compromise protection.

When PPE isn't worn as intended, even the most carefully developed safety policies can fail to deliver the protection they were designed to provide.

Where does the disconnect begin?

Research conducted by Alsico, which surveyed 251 professionals across the electrical sector (150 uniform wearers and 101 individuals responsible for choosing protective uniforms), indicated a disconnect between procurement priorities and the reality on the ground.

Only around a quarter of procurement and safety respondents said comfort had the most significant influence on their selection choices, whilst almost half of workers said they would be more inclined to wear their protective uniform if it were more comfortable.

With environmental factors such as rising temperatures and increasingly physically demanding working environments having more of an impact, the tension between protection and comfort is becoming even more apparent.

The ‘wearer gap’ reflects the difference between what organisations intend and what happens in practice. Compliance is often viewed as a behavioural problem, but in many cases, workers are not deliberately ignoring procedures. They are responding to discomfort, poor fit or clothing that is impractical for the conditions they are working in.

The knowledge gap

The same research found that almost a quarter (23%) of workers said they had never been shown how to wear their protective clothing correctly, while one in five workers admitted they did not know the risks associated with not wearing their PPE properly.

In high-risk roles, especially where equipment can’t always be de-energised, workers need clothing that can withstand extreme temperatures, UV radiation and thermal energy.

Arc flash is one of the most dangerous yet often misunderstood hazards in electrical environments. With temperatures hotter than the surface of the sun and risks including severe burns, blindness and fatalities, understanding and mitigating arc flash risk is critical for businesses operating with or around high- or low-voltage systems.

Whilst workers are skilled and well versed in their roles, their understanding of the vital role of PPE in protecting against dangers such as arc flash clearly requires improvement.

Too often, training focuses on the hazard itself without explaining how the garment provides protection, why every component matters or what can reduce its effectiveness. Organisations cannot assume employees understand how their protective clothing works simply because they have been issued with it.

Workers may know they need to wear arc-rated clothing; however, they may not understand why fastening every closure, wearing the correct underlayers or replacing damaged garments is critical to maintaining protection.

The importance of communication channels

Closing this knowledge gap does not necessarily require major investment. In fact, small changes in communication can have a significant impact.

Practical toolbox talks, refresher sessions and demonstrations that explain how protective clothing functions can reinforce safe behaviours far more effectively than simply reminding workers to comply with policy.

Regular feedback between those wearing uniforms and those providing them is critical to improving safety outcomes. Regular surveys, quarterly uniform reviews or simple on-site conversations can allow companies to identify issues that may be causing workers to wear their uniforms incorrectly or even choose to wear their own clothing.

Communication should be continuous rather than one-directional. Workers are often the first to identify where garments restrict movement, become uncomfortable or fail to suit changing conditions. Capturing this feedback allows organisations to refine both specification and training before poor habits become embedded.

For procurement professionals, staying up to date with guidance on inclusive PPE, new materials and the range of PPE options available can also help build an understanding of what is changing within the market and how this could benefit their workforce.

Improving compliance starts with listening to the people wearing the clothing. By responding to worker feedback and selecting garments that balance comfort with protection, procurement and safety teams can help ensure PPE is worn correctly throughout the working day.

An ongoing commitment to improving day-to-day safety

PPE specification should not be viewed as a one-off procurement exercise. As fabrics, garment technologies and working practices evolve, organisations should regularly review whether existing clothing continues to meet operational needs while encouraging compliance.

Ultimately, compliance cannot be achieved through policy documents alone. Organisations need risk assessments that reflect real working conditions, PPE that workers can wear comfortably throughout the day, training that explains not just what to wear but why it matters, and open communication that allows issues to be identified early.

When specification, education and worker engagement come together, the gap between policy and practice begins to close, creating safer behaviours that become part of everyday working life.