Personal protective equipment (PPE) is critical to your safety if you work in the utility, gas, oil, or electrical industries. When you’re exposed to arc flash, flash fire, chemical exposure or traffic hazards, your gear must be up to the task. However, we often see workers making avoidable mistakes that put them at risk, despite having the right PPE on hand.
We manufacture flame-resistant rain gear for electrical linemen and crews who work in high-risk environments. Based on over 40 years of experience serving the field, we want to share the five most common PPE mistakes and how to avoid them.
Wearing Damaged or Non-Compliant PPE
What is a common fault for personal protective equipment?
A common fault with personal protective equipment is continued use after the gear is damaged or no longer meets safety standards. Torn seams, faded labels, and worn closures can compromise your protection during an arc flash or flash fire. Unfortunately, this is one of the most frequent mistakes we see.
Rain gear that has faded and no longer has the high visibility performance due to wear, age, or UV exposure is no longer safe. The same is true for gear that was never rated for your work environment in the first place.
How to avoid damaged or non-compliant PPE:
Inspect your PPE before every shift. Run your hands along the seams. Look for fabric that feels thin or stiff. Ensure the safety labels are intact and readable. Our flame-resistant rain gear is tested to meet NFPA and ASTM standards, but no gear lasts forever. When you notice signs of failure, it’s time to replace it.
Using the Wrong Gear for the Job
How do I know if I have the right PPE gear?
Choosing the wrong gear for the task is another major risk. For example, standard rain gear may be waterproof but offers no protection against electrical hazards or flash fire. In environments where arc flash or fire exposure is possible, that kind of gear can put your life in danger.
Electrical lineman rain gear should be flame-resistant and designed to protect you in specific ways. Arc-rated gear protects from electrical arc flash, while flame-resistant gear is intended for use in environments where flash fire is a risk. Using anything else leaves you exposed.
How to avoid the wrong PPE gear:
Always match your gear to your hazard exposure. If you work on energized lines or in substations, use certified electrical lineman rain gear that meets ASTM F1891. If you work in oil and gas environments where flash fire is a risk, use flame-resistant rain gear that meets ASTM F2733. We clearly label each of our products so you know exactly what you’re getting.
Wearing PPE That Doesn’t Fit Properly
What are the 5-point PPE safety rules?
The 5-point PPE safety guidelines cover protection for the head, eyes and face, hands, body, and feet. Failing to cover any of these areas or wearing PPE that doesn’t fit properly undermines your safety.
Improperly fitted PPE can leave critical areas exposed. Loose hoods may not stay in place or could be a snag hazard. Tight sleeves may ride up. Ill-fitting gear can also reduce range of motion, making your job harder and more dangerous.
How to avoid PPE that doesn’t fit well:
Wear gear that fits comfortably over your work uniform. Make sure zippers close fully and cuffs are secure. When your rainwear fits right, it stays in place through every movement. Our electrical lineman rain gear comes in a wide range of sizes including long and tall sizes with configurations to help you stay covered and productive.
Skipping Regular PPE Inspections
How often should PPE be inspected?
PPE should be inspected before every shift. You should also complete more detailed checks weekly or anytime gear is exposed to extreme conditions. Ignoring inspections is one of the top reasons gear fails unexpectedly.
We often hear from crews who store rain gear in toolboxes, vehicles, or other places where moisture and dirt can accumulate. These conditions shorten the life of the fabric and may damage flame-resistant coatings or arc-rated protection.
How to avoid skipping PPE inspections:
Make inspection part of your daily routine. Before use, check for holes, discoloration, missing snaps, or damaged closures. Water-resistant coatings should still repel liquid. Flame-resistant rain gear should feel consistent and show no signs of breakdown. If anything looks or feels off, remove it from service and report the issue.
Ignoring Care and Cleaning Instructions
How should I clean my FR rain gear?
Flame-resistant rain gear is built for tough jobs, but it must be maintained properly. High heat, harsh chemicals, and improper laundering can destroy the properties that keep you safe. In some cases, we’ve seen workers accidentally remove protective treatments simply by washing the gear incorrectly.
Leaving your rain gear wet in a truck or locker can also lead to mildew, mold, and odor, and may weaken the fabric.
How to avoid laundering errors:
Always read and follow the care label. Use mild detergent without bleach. Line dry or tumble dry with no heat for best results. Store gear in a clean, dry location. Our gear comes with care guides to make this process clear and simple. These steps not only preserve your protection but also extend the life of your investment.
Final Reminder: Protection Depends on Proper Use
Even the best flame-resistant rain gear can fail if it is misused, ignored, or not maintained. PPE is only effective when used correctly, inspected regularly, and matched to the hazards of the job.
The work you do is critical—and dangerous. Your gear needs to perform every day, under pressure, in the worst conditions. Avoiding these five common mistakes can help you stay safer and more confident on the job.
If you’re ready to upgrade your gear or need protection that meets strict safety standards, we invite you to shop our complete line.
Explore our complete selection of certified electrical linemen and flame-resistant rain gear built for high-risk work environments.
Make safety part of your routine. Get the right gear, and use it the right way—every time.
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