Top PPE Mistakes in Hot Weather and How to Prevent Them

When the temperature rises, so do the safety risks. For workers relying on Personal Protective Equipment (PPE), heat, humidity, and sun exposure can reduce the gear’s effectiveness putting lives at risk if not properly maintained.

Sweat can affect how PPE fits and performs. UV rays and heat can weaken materials faster than expected. And poor habits like skipping inspections or storing gear improperly only increase the danger. That’s why summer is the right time to reinforce PPE protocols.

Here are the most common PPE mistakes in hot weather and how safety managers can proactively prevent them.

1. Skipping Regular PPE Inspections

PPE can’t protect if it’s damaged, expired, or used incorrectly and in summer, wear and tear accelerates. Yet one of the most common oversights is skipping daily or routine inspections.

Why this matters:

Small defects like cracked seals, frayed harnesses, or worn padding can go unnoticed until it’s too late. Heat and heavy use only speed up this damage. Without inspections, faulty gear may be used in critical tasks, increasing the chance of injury or OSHA violations.

What to do:

Perform daily visual checks before each use (OSHA 29 CFR 1910.132 requires this for all general PPE)
Conduct documented inspections for items like fall protection (per OSHA 1926.502)
Tag damaged gear “out of service” and replace immediately

By making inspections a daily habit, teams can identify problems early, extend PPE lifespan, and avoid preventable failures.

PPE doesn’t last forever—especially in summer. Exposure to UV rays, sweat, and heavy usage takes a toll, even on high-quality gear. Knowing when to replace PPE is key to keeping workers safe.

2. Improper Storage of PPE and Chemicals

In summer, storage mistakes can have serious consequences—especially for PPE exposed to chemicals or hazardous materials. High temps and humidity can degrade chemical containers, or the PPE designed to protect against them.

Key risks include:

Accelerated chemical reactions or leaks
Weakened PPE integrity (e.g., gloves, face shields)
Fire hazards from volatile or improperly stored substances

Storage tips:

Use OSHA- and NFPA-compliant cabinets (e.g. Justrite®)
Separate incompatible chemicals
Keep storage areas clean, labeled, and away from hoistways or exterior walls

Proper storage not only protects workers—it ensures compliance and keeps facilities audit-ready.

3. Overlooking Damage to Fall Protection Equipment

Fall protection gear is one of the most critical and vulnerable types of PPE in the heat. Prolonged sun exposure can make harnesses brittle or discolored. Sweat and dirt can reduce flexibility and hide signs of wear.

A dangerous assumption: A harness may look fine on the outside but be compromised internally. Fall protection relies on elasticity during a fall and any loss of stretch or unnoticed damage could be life-threatening.

What to check:

Harnesses: Frayed webbing, stretched D-rings, corroded buckles
Lanyards: Cuts, worn shock absorbers
Connectors: Rust, locking failures

Recommended steps:

Train workers to inspect by touch as well as sight
Maintain inspection logs
Follow replacement schedules based on usage and manufacturer guidance

Arbill offers OSHA- and ANSI-compliant fall protection systems, plus training to help your team recognize damage before it leads to disaster.

4. Using Worn or Expired PPE

PPE doesn’t last forever—especially in summer. Exposure to UV rays, sweat, and heavy usage takes a toll, even on high-quality gear. Knowing when to replace PPE is key to keeping workers safe.

Common signs it’s time to replace gear:

Gloves: Visible holes, slick grip, thinning fabric
Hard Hats: Cracks, fading, signs of sun damage
Respirators: Cracked facepieces, damaged straps or filters
High-Vis Vests: Faded color, peeling reflective tape
Safety Glasses: Scratched lenses, loose or broken arms

Creating simple replacement guidelines and educating teams on these indicators can help eliminate guesswork—and ensure nothing worn out makes it onto the jobsite.

5. Gaps in PPE Training

The best PPE is only as effective as the person using it. In hot weather, where equipment is more likely to shift, fail, or degrade, proper training becomes even more critical.

Why training matters in the summer:

Sweat and heat alter how PPE fits and functions
Workers may cut corners or misuse equipment to stay cool
Seasonal workers may lack the same knowledge as full-time staff

Training requirements to keep in mind:

OSHA requires PPE training at assignment and whenever duties, equipment, or hazards change
Temporary and seasonal workers must be trained before exposure to any hazard
Refresher training—even if not required annually—helps reduce risk and reinforce If your current training program needs updating, Arbill can help tailor a standards-based approach to your environment.

Final Thoughts: Protecting Workers in the Heat

PPE failures don’t happen overnight, but they do happen fast when summer conditions are ignored. Heat, humidity, and UV exposure introduce risks that require proactive action.

Key takeaways:

Inspect PPE daily, don’t rely on looks alone
Store chemicals and PPE properly to prevent breakdown
Train workers consistently, especially temporary or summer staff
Replace worn gear before it fails

At Arbill, we help safety leaders simplify PPE management with expert-led assessments, purpose-built gear for extreme environments, and training programs that stick.