Module 2: Hazard Assessment and Selection

In this module

Objectives covered: LO 1.2.1. By the end you will be able to:

Carry out a simple PPE hazard assessment, step by step.
Match each type of hazard to the part of the body at risk and the PPE that protects it.
Build a PPE matrix for the tasks in a work area.
Check that different PPE items work together and fit every worker.

2.1 Why assess before you buy?

Buying PPE without an assessment is like buying medicine without a diagnosis. You may spend money and still leave people unprotected. OSHA 1910.132(d) requires the employer to assess the workplace, choose PPE from the findings, and certify the assessment in writing. The written certification must show:

the workplace that was evaluated,
the name of the person certifying that the evaluation was done,
the date of the assessment, and
that the document is a certification of hazard assessment.

2.2 Six steps of a PPE hazard assessment

Walk the area. Watch the real work on the real shift. Talk to the operators and technicians.
List the tasks. Include routine work, maintenance, cleaning and emergencies.
Identify the hazards for each task using the categories in the table below. Check Safety Data Sheets (SDS) for every chemical.
Rate the risk. A simple 5 by 5 matrix of likelihood times severity is enough for most areas.
Apply higher controls first, then decide what PPE is still needed.
Record, communicate and review. Review when a process, machine or chemical changes, after an incident, and at least once a year.

2.3 Hazards, body parts and PPE

Hazard type	Typical source	Body part	Typical PPE
Impact and flying particles	Grinding, chipping, hammering	Eyes, face, head	Safety glasses, face shield, helmet
Falling objects	Overhead cranes, scaffolds	Head, feet	Helmet, safety shoes with toe cap
Cuts and punctures	Sheet metal, glass, knives, nails	Hands, feet	Cut-resistant gloves, puncture-resistant soles
Chemicals	Acids, alkalis, solvents, dyes	Eyes, skin, lungs	Goggles, chemical gloves, apron, respirator
Heat and molten metal	Furnaces, welding, casting	Whole body	Aluminised or leather clothing, face shield
Dust, fumes, gases	Cement, welding, ammonia	Lungs	Respirator matched to the contaminant
Optical radiation	Arc welding, cutting, lasers	Eyes, skin	Welding helmet with correct shade
Electricity	Panels, substations	Whole body	Insulating gloves, arc-rated clothing
Noise	Looms, generators, compressors	Ears	Earplugs, earmuffs
Falls from height	Roofs, scaffolds, ship hulls	Whole body	Full-body harness system

2.4 The PPE matrix

A PPE matrix turns the assessment into a simple chart that anyone can read. Post it at the entrance of each area, in Bangla and English, with pictures.

Bangladesh industry example: steel re-rolling mill, Chattogram

Task	Helmet	Eye / face	Gloves	Footwear	Hearing	Other
Furnace charging	Yes	Face shield + glasses	Heat-resistant	Safety boots, heat-resistant sole	Yes	Aluminised jacket
Rolling stand operator	Yes	Safety glasses	Leather	Safety boots	Yes	Cotton coverall (no synthetics)
Crane slinging	Yes, with chin strap	Safety glasses	Leather	Safety boots	Yes	Hi-vis vest
Maintenance welding	Yes	Welding helmet, shade 10 to 12	Welding gauntlets	Safety boots	Yes	Leather apron, fume respirator

2.5 Compatibility and fit

Check that items work together: earmuffs must seal around safety glasses; goggles must not break a respirator seal; a face shield must fit the helmet.
Buy a range of sizes. In the RMG and footwear sectors many workers are women, and gloves, boots and harnesses made only in large sizes will not protect them.
Let workers try PPE before bulk purchase. Comfortable PPE gets worn; uncomfortable PPE gets taken off.
Think about heat. In Bangladesh summers, choose breathable materials where the hazard allows, and plan rest breaks.

Learning Check

Answer these two questions to check your understanding. You can try again as many times as you like.