Beyond The Vest: High-Visibility PPE for Industrial Workplaces

People selecting and loading materials in busy warehouses need high-visibility PPE that gets them noticed in low-light conditions. Image courtesy of RefrigiWear.

Best practices for safety gear keep employees safe and productive.

By: Leigh Stadelmeier, Contributor

In a fast-paced industrial environment, being seen is the first step to staying safe. In warehouses, on loading docks, or around trucks and forklifts, one blind spot can cause severe injury in a split second. Wearing high-visibility PPE is the simplest way to cut that risk. However, high-visibility safety gear only works if employers choose the right gear, enforce its use, and maintain it properly.

Industrial safety managers must understand the framework of standards for high-visibility safety gear, avoid common compliance pitfalls, and apply best practices to keep their employees safe and productive.

WHY HIGH-VISIBILITY PPE MATTERS IN INDUSTRIAL SETTINGS

High-visibility PPE is often associated with road construction but is equally critical in warehouses, manufacturing plants, and distribution centers.

Struck-by accidents are still one of the biggest causes of serious injuries. Forklifts cause tens of thousands of accidents yearly, often because drivers can’t see people in dark, crowded, or cluttered areas. Picture a tight aisle where a lift rounds the corner, a loading dock with trucks backing in, or an outdoor yard on a rainy night.

In all these situations, high-visibility apparel provides critical recognition distance, giving the seconds they need to hit the brakes and avoid disaster.

STANDARDS FOR HIGH-VISIBILITY APPAREL

The American National Standards Institute (ANSI) partners with the International Safety Equipment Association (ISEA) to set standards for high-visibility safety apparel. The Occupational Safety and Health Administration (OSHA) adopted ANSI/ISEA 107 as the minimum standard for visibility in specific work environments. Industrial employers that provide non-compliant gear can be cited under the General Duty Clause.

“Because ANSI/ISEA 107 is OSHA’s benchmark for high-visibility apparel, it’s important for safety managers to know how PPE is classified within the standard, so they can select the right gear to protect employees in their specific work environments,” explains Cody Hughes, Director of Design and Quality at RefrigiWear, a leading manufacturer of insulated high-visibility workwear. As a member of ISEA, Hughes participates in standards development for several product groups, including the High Visibility Product Group, which is responsible for the ANSI/ISEA 107 standard.

TYPES & PERFORMANCE CLASSES

The current standard, ANSI/ISEA 107-2020, classifies garments into three basic types:

• Type O for off-road sites like warehouses or yards
• Type R for roadway work or areas with nearby traffic
• Type P for public safety professionals such as police, fire, and EMS

Within those types, high-visibility garments are further classified into Performance Classes 1, 2, and 3, based on the amount of bright background fabric and reflective tape. Class 1 may be sufficient for low-risk areas with little vehicle movement, while Class 3 provides the highest visibility in high-speed or complex environments. High-visibility apparel labeled Class E is considered supplemental and can be added to an outfit to raise the overall Performance Class rating.

The current standard also requires 360-degree visibility, labeling, and performance testing to ensure gear works as intended, but Hughes explains that changes are on the horizon.

REVISIONS TO THE CURRENT STANDARD

“A revision to the ANSI/ISEA 107 standard is expected to be published later this year that may include revised protocols for evaluating colorfastness, dimensional stability and tear resistance. A major revision is also expected in the sizing section of the standard to introduce more precise measurement protocols and minimum dimension requirements to improve garment fit across a broader range of body types,” says Hughes.

These changes are expected to clarify the requirements for garments meeting ANSI/ISEA 107 standards and make it easier for employers to outfit employees of all shapes and sizes with proper high-visibility safety gear for their jobs.

“Choosing high-visibility PPE that meets the updated standard will be a proactive investment in worker safety and operational efficiency,” adds Hughes.

Workers in industrial settings need high-visibility PPE and workwear that stands out against the background of the work environment. Image courtesy of RefrigiWear.

COMMON COMPLIANCE CHALLENGES

Despite acknowledging the importance of high-visibility gear, compliance lapses are common.

One issue is improper garment selection. Employers may issue Class 1 vests in warehouses where forklifts move quickly or lighting is poor, when Class 2 or 3 would be safer.

Another challenge is training employees in the proper use and care of their high-visibility gear. Fluorescent colors fade, reflective tape peels, and dirt reduces visibility. OSHA has cited employers for allowing worn-out gear that no longer provides adequate protection.

Overlapping PPE requirements can also cause problems. For example, workers in arc-flash or chemical environments may need flame-resistant gear, which may be hard to find in high-visibility colors. These conflicting requirements require practical policies that make it exceedingly clear which types of PPE are required for which types of tasks, and those requirements may differ by location or environment.

Finally, employers should avoid procurement pitfalls. While buying cheap gear may save money upfront, it can lead to faster wear, more frequent replacement, employee discomfort and dissatisfaction, and increased long-term costs.

BEST PRACTICES FOR INDUSTRIAL SAFETY MANAGERS

To close these compliance gaps, employers and safety managers can take proactive steps:

• Conduct a Hazard Assessment

Evaluate each work zone and task. Indoor forklift traffic may justify Type O, Class 1 or Type R, Class 2 garments, while outdoor yard work near vehicle traffic may require Type R, Class 3.

• Specify ANSI/ISEA Compliance in Contracts

Procurement documents should require ANSI/ISEA 107 garments, not just “high-visibility clothing. “Every compliant garment must have a tag showing the standard it meets, as well as the Type and Performance Class.

• Check for Durability

Check maximum wash cycles and whether reflective tape is stitched, heat-applied, or segmented. Build quality affects the useful life of the PPE.

• Establish Inspection & Replacement Cycles

Train supervisors to inspect garments during routine safety checks. Replace any gear that is torn, faded, or doesn’t provide a proper fit.

• Integrate Training into Onboarding

Workers should know not only when to wear high-visibility PPE, but why. Reinforce policies during safety meetings and refresher courses.

• Select Ergonomic, Task-Appropriate Garments

Comfort drives compliance. Proper sizing, lightweight gear for hot conditions, insulated high-visibility freezer wear for cold storage, and high-visibility FR (if needed) all improve compliance with PPE and safety policies.

• Plan for Special Environments

Where workers face dual hazards—low visibility plus fire, chemical, or weather risks—procurement managers should prioritize garments that meet multiple standards simultaneously.

• Prepare for the Updated Standards

Forward-thinking safety managers should review their PPE policies to ensure compliance with the current ANSI/ISEA 107-2020 standard and work with suppliers who are preparing for compliance with the forthcoming update.

HIGH-STAKES FOR SAFETY

High-visibility gear is one of the least costly PPE investments, but its value in preventing accidents is priceless.

In busy warehouses and yards, it’s the first line of defense against forklifts, trucks, and blind spots. The real challenge isn’t just handing out gear—it’s choosing the right high-visibility PPE for the task at hand, keeping it in good shape, and making sure it’s worn every shift.

Compliance matters, but the real goal is simple: every worker gets home safe. WMHS

Leigh Stadelmeier is an Authorized OSHA Outreach Trainer and Vice President of B2B Outdoor Sales for RefrigiWear, the leading manufacturer of industrial insulated workwear, safety apparel, and personal protective equipment (PPE) for extreme cold work environments. Having experienced a traumatic fall while serving in the Army, Stadelmeier devotes his career to sharing safety gear and training to prevent accidents on the job. Visit: https://pro.refrigiwear.com/