Common PPE Mistakes in Healthcare & Aged Care — and How to Prevent Them

Personal protective equipment (PPE) is a critical part of infection prevention in healthcare and aged care environments. From protecting staff during routine care to reducing the risk of outbreaks among vulnerable residents and patients, PPE plays a vital role in keeping everyone safe.

Yet despite clear guidelines and widespread experience, PPE mistakes still happen — even among highly trained and dedicated professionals. Long shifts, high workloads, staffing pressures, and the repetitive nature of care tasks can all contribute to small lapses that carry real consequences. In many cases, these errors are not the result of negligence, but of systems under strain and environments where speed and urgency are constant.

In healthcare and aged care settings, where close contact is unavoidable and residents may be immunocompromised or frail, even minor PPE missteps can increase the risk of cross-contamination and infection spread.

Why PPE use is especially critical in healthcare and aged care

Healthcare and aged care settings present unique challenges when it comes to infection prevention. Unlike many other workplaces, care environments involve frequent, close, and often prolonged contact with patients and residents, making the correct use of PPE especially important.

Many individuals in these settings are more vulnerable to infection due to age, chronic illness, weakened immune systems, or recent medical procedures. What might be a mild infection for a healthy person can have serious consequences for an older adult or hospital patient.

Care staff also move between multiple rooms, residents, and tasks throughout a shift. Without consistent PPE use and careful donning and doffing, there is a real risk of unintentionally transferring pathogens from one person or surface to another. 

In both healthcare and aged care, exposure risks are not limited to high-risk procedures. Everyday tasks such as assisting with hygiene, administering medication, or providing personal care can involve contact with:

• Respiratory droplets
  
• Bodily fluids
  
• Contaminated surfaces or shared equipment

This is why staff are often required to wear a combination of PPE items — including masks, eye protection, gowns, and gloves — depending on the level of risk, rather than relying on a single protective measure.

The pace and intensity of care work can also lead to fatigue and time pressure, increasing the likelihood of shortcuts. In environments where PPE is used repeatedly throughout long shifts, even small lapses can compromise infection prevention efforts.

For these reasons, PPE in healthcare and aged care is not just a precaution — it is a fundamental safeguard. Having a clear understanding of which PPE is required for droplet precautions and how each item works together helps protect patients, residents, staff, and the wider community.

Common PPE mistakes in healthcare and aged care

Even in well-established healthcare and aged care environments, PPE mistakes are common. In most cases, they occur not because staff don’t care, but because of time pressure, fatigue, training gaps, or system limitations. 

Below are some of the most frequently observed PPE mistakes in care settings.

Mistake 1: Wearing the wrong type of PPE for the task

One of the most common issues is using PPE that doesn’t match the level of risk. This may include:

• Wearing a surgical mask when a respirator is required
  
• Using gloves alone without additional protection when splashes or droplets are possible
  
• Choosing the wrong gown or apron for exposure risk

This often happens when risk assessments aren’t updated, or when staff rely on habit rather than task-specific guidance.

Mistake 2: Incorrect donning and doffing

PPE only protects when it’s put on and removed correctly. Errors during donning and doffing can lead to self-contamination, particularly when:

• Steps are skipped to save time
  
• PPE is removed in the wrong order
  
• Contaminated surfaces are touched during removal

In busy care environments, even experienced staff can slip into unsafe routines if refresher training isn’t reinforced.

Mistake 3: Reusing disposable PPE incorrectly

Single-use PPE is designed for one interaction or task. Common issues include:

• Wearing the same mask or gloves between residents
  
• Removing PPE and reusing it later
  
• Extending use beyond intended limits

These practices often arise during staffing shortages or high workload periods, but they significantly increase infection risk.

Mistake 4: Poor fit or ill-fitting PPE

Ill-fitting PPE reduces effectiveness and comfort. Examples include:

• Loose masks with gaps around the nose or cheeks
  
• Gloves that are too large or too tight
  
• Gowns that don’t fully cover clothing

When PPE is uncomfortable or restricts movement, staff are more likely to adjust it or remove it prematurely.

Mistake 5: Touching PPE during use

Touching PPE while providing care can transfer contamination from surfaces to hands or the face. This includes:

• Adjusting masks with unclean hands
  
• Touching face shields or gowns mid-task
  
• Frequently repositioning PPE due to discomfort

Each contact increases the risk of self-contamination and spread between patients or residents.

Mistake 6: PPE fatigue and complacency

In settings where PPE is worn continuously, fatigue can lead to complacency. Over time, staff may:

• Take shortcuts during routine care
  
• Become less vigilant with donning and doffing
  
• Treat PPE as background equipment rather than a safety barrier

This is especially common during long shifts or extended outbreak periods.

Mistake 7: Inadequate PPE training or refreshers

Initial PPE training is essential, but not sufficient on its own. Mistakes occur when:

• New staff are not fully trained
  
• Training isn’t refreshed regularly
  
• Updates to PPE guidance are not clearly communicated

Without ongoing reinforcement, correct PPE use can gradually drift from best practice.

How to reduce PPE mistakes in care settings

Reducing PPE mistakes in healthcare and aged care settings requires more than reminders or checklists. It depends on supportive systems, clear guidance, and an environment that enables staff to do the right thing — even under pressure.

The following strategies focus on practical improvements that help PPE work as intended in real-world care environments.

Provide clear, task-based PPE guidance

PPE requirements should be clearly linked to specific tasks and risks. This includes:

• Clear protocols for standard, contact, droplet, and airborne precautions
• Simple visual guides showing which PPE items are required for different care activities
  
• Consistent messaging across policies, signage, and training materials

When expectations are clear, staff are less likely to rely on habit or guesswork.

Reinforce correct donning and doffing practices

Donning and doffing errors are a major source of contamination risk. To reduce this:

• Provide regular refresher training, not just one-off sessions
  
• Display step-by-step posters in PPE donning and removal areas
• Encourage staff to slow down during PPE removal, especially after high-risk tasks

Ensure PPE is readily available and easy to access

PPE mistakes often occur when equipment is hard to find or inconvenient to use. Care settings should ensure:

• PPE is stocked at point-of-care locations
  
• Correct sizes are available for all staff
  
• Storage areas are well-organised and clearly labelled

Address fit and comfort issues

Poor fit and discomfort increase the likelihood of PPE being adjusted or removed incorrectly. Reducing this risk involves:

• Offering a range of PPE sizes and styles
  
• Ensuring masks and respirators fit properly and comfortably
  
• Supporting fit testing where required

Read related article: The Importance of Respiratory Fit Testing in Occupational Safety

Normalise speaking up about PPE concerns

Staff should feel supported to raise PPE-related concerns without fear of blame. This includes:

• Encouraging peer reminders and double-checks
  
• Responding constructively to reported issues
  
• Treating PPE errors as learning opportunities rather than individual failures

Support staff through fatigue and workload pressures

Fatigue significantly increases the risk of PPE lapses. Practical steps include:

• Reviewing staffing levels and task allocation
  
• Scheduling breaks where possible
  
• Rotating high-risk tasks during long shifts

Monitor, review, and improve PPE practices

Continuous improvement helps PPE programs remain effective. This may involve:

• Observational audits focused on learning, not punishment
  
• Reviewing incident and near-miss reports
  
• Updating training and protocols based on real-world feedback

Choosing the right PPE for healthcare and aged care

Selecting appropriate PPE in healthcare and aged care settings isn’t just about availability — it’s about ensuring each item is fit for purpose, compliant with recognised standards, and suitable for the level of risk involved. 

Masks and respirators

Surgical / Medical masks

• Purpose: Protect against large respiratory droplets and splashes
  
• Common use: Routine patient care, droplet precautions

Relevant standards may include:

• AS 4381 (Australia – single-use face masks)
  
• ASTM F2100 (international standard commonly referenced in healthcare)
  
• EN 14683 (medical face masks – international equivalent)

These masks are not designed to provide a tight seal or protect against airborne particles.

Respirators (P2, N95, FFP2)

• Purpose: Protect the wearer from inhaling airborne particles and aerosols
  
• Common use: Airborne precautions, higher-risk procedures, outbreak settings

Key standards include:

• AS/NZS 1716 – Australian/New Zealand certification for respirators (e.g. P2)
  
• NIOSH N95 – United States respirator standard
  
• EN 149 (FFP2) – European respirator standard

In healthcare and aged care workplaces, respirators should be:

• Certified to a recognised standard
  
• Used in accordance with AS/NZS 1715 (selection, use, and management)
  
• Fit tested where required

Need fit testing for your workplace? Aussie Pharma Direct offers accredited fit testing services on-site and off-site. Click here for more information. 

Gloves

Purpose: Protect hands from contact with blood, bodily fluids, and contaminated surfaces

Common types: Nitrile, latex, vinyl (nitrile is often preferred for infection control)

Relevant standards include:

• EN 455 – Medical gloves for single use
  
• ASTM D6319 (nitrile gloves)
  
• AS/NZS 4011 (examination gloves – where applicable)

Gloves must be:

• Single-use
  
• Changed between patients and tasks
  
• Used alongside hand hygiene — not as a replacement

Read related article: What are the Differences between Nitrile, Vinyl & Latex Gloves?

Gowns and aprons

Purpose: Protect clothing and skin from splashes, droplets, and contamination

Common use: Personal care, isolation rooms, procedures with splash risk

Relevant standards include:

• AS/NZS 4501 – Protective clothing for healthcare workers
  
• AAMI PB70 (international reference for barrier performance levels)

When selecting gowns, consider:

• Level of fluid resistance required
  
• Coverage (full gown vs apron)
  
• Task duration and exposure risk

Eye and face protection

Purpose: Protect eyes and face from splashes, droplets, and aerosols

Types: Goggles, face shields

Relevant standards include:

• AS/NZS 1337 – Eye and face protection for occupational use

Eye protection should:

• Fit securely and comfortably
  
• Be compatible with masks or respirators
  
• Be cleaned or disposed of according to manufacturer guidance

Head and foot protection (where required)

While not always required, head covers and shoe covers may be used in:

• High-risk isolation areas
  
• Outbreak response settings
  
• Certain procedures

These items should be:

• Single-use or appropriately reprocessed
  
• Used in line with facility infection control protocols

Why standards matter in care settings

Standards and certifications provide assurance that PPE:

• Has been tested for its intended purpose
  
• Meets minimum performance and safety requirements
  
• Can be relied upon as part of an infection control program

However, certified PPE is only effective when it is:

• Matched to the task and level of risk
  
• Correctly fitted and worn
  
• Used consistently and disposed of appropriately

PPE works when systems support people

In healthcare and aged care settings, PPE is more than just equipment — it’s a critical part of protecting people who are often at their most vulnerable. While guidelines and standards are essential, PPE only works as intended when it is chosen correctly, worn properly, and supported by strong systems and workplace culture.

Many PPE mistakes occur not because staff lack care or commitment, but because of fatigue, time pressure, and practical constraints. Recognising these challenges allows organisations to move beyond blame and focus on meaningful improvements — such as clearer guidance, regular training, adequate supply, and leadership support.

Choosing PPE that meets recognised standards is an important first step, but it must be paired with:

• Proper fit and comfort
  
• Consistent donning and doffing practices
  
• Ongoing training and refreshers
  
• An environment where staff feel supported to speak up

When healthcare and aged care organisations invest in both the right PPE and the right processes, they create safer environments for staff, patients, and residents alike.

Ultimately, reducing PPE mistakes is about building systems that help people do the right thing — every time, even under pressure.

PPE That Supports Infection Control in Care Settings