The UK’s Health and Safety Executive (HSE) has warned that poor management of personal hearing protection is leaving workers at risk of permanent damage, regardless of investment in earplugs or earmuffs.
Personal protective equipment sits at the bottom of the hierarchy of control because it requires constant attention and correct use.
Unlike engineering solutions that operate automatically, hearing protection depends on training, supervision and individual behaviour.
“This isn’t about blame – it’s about recognising a key challenge,” said Chris Steel, HSE’s principal specialist inspector.
From inspections across workplaces, HSE has found recurring weaknesses in how companies provide, maintain and monitor hearing protection.
Equipment in poor condition is a common problem: earmuffs with cracked seals or stretched headbands provide little protection, while single-use earplugs lose their effectiveness once removed and should not be reused. Inspectors also reported cases where moulded plugs had been worn for decades, despite changes in ear canal shape and material degradation.
Accessibility is another issue. Protection must be available where and when workers need it, not stored away. HSE highlighted examples where employees had to walk long distances to fetch their plugs after already entering noisy environments. Incorrect fitting is also widespread.
The CUFF approach
Earplugs require proper insertion technique, while earmuffs can fail if worn over hats, hoods or hair accessories. In addition, not all workers can use the same protection, so employers are required to offer suitable alternatives.
Technical suitability is equally important. Each product carries a Single Number Rating (SNR) that should match actual workplace noise levels. Over-protection brings its own risks by preventing workers from hearing alarms and safety signals.
To help employers manage these challenges, HSE promotes the CUFF approach: condition, use, fit and fit for purpose.
This framework ensures that hearing protection is effective, appropriate and compliant.
Personal hearing protection demands active management rather than passive provision, according to Steel. Once hearing damage occurs, it cannot be reversed.
“Hearing protection is useless sitting in storage whilst workers operate noisy equipment,” Steel added. HSE emphasises that companies who properly manage their programmes not only reduce injury rates and strengthen compliance, but also protect something irreplaceable: the long-term hearing of their workforce.
