Preventing Hearing Loss in Industrial Settings

© Adisorn – stock.adobe.com

Best practices for effective hearing protection.

By: Rick Pedley, Contributor

Imagine working in a loud industrial environment — machines humming, tools clanking, forklifts beeping. It’s just another day on the job for millions of U.S. workers. However, while hazards like falls or chemical spills are focal points of workplace safety, noise-induced hearing loss often goes unnoticed. Unlike traumatic injuries, hearing damage creeps in gradually, making it easy to ignore — until it’s too late.

WHY YOU CAN’T OVERLOOK INDUSTRIAL NOISE POLLUTION 

Many workers and employers underestimate the long-term consequences of prolonged noise exposure. The effects aren’t immediate, and without visible warning signs, hearing loss is often dismissed as an inevitable part of the job. According to the National Institute for Occupational Safety and Health (NIOSH), around 22 million US workers are exposed to potentially damaging noise at work each year, with other sources estimating that the actual figure could be as high as 30 million.¹

Far too often, workers assume they can adapt to the noise or that “it isn’t that bad.” However, even noise levels that seem tolerable over short periods can cause cumulative damage with prolonged exposure. Forklifts, packaging equipment, conveyors, compressed air tools, and ventilation systems can all produce sound levels well above the 85-decibel (dBA) threshold, which OSHA identifies as hazardous over an eight-hour exposure.²

Unlike potential hazards like crushing injuries or burns, noise pollution doesn’t always produce immediate symptoms. Instead, workers may notice trouble understanding speech, ringing in the ears (tinnitus), or general fatigue caused by auditory strain. Left unchecked, hearing loss can degrade job performance, reduce situational awareness, and increase the likelihood of communication-related errors — especially in critical, fast-paced environments where verbal cues can spell the difference between safety and disaster.

UNDERSTANDING NOISE REDUCTION RATINGS 

Before rushing to purchase hearing protection, such as earplugs or noise-canceling earmuffs, it’s important to understand Noise Reduction Ratings (NRR). This value, measured in decibels (dB), indicates how much sound the device can block under ideal laboratory conditions. For instance, earmuffs with an NRR of 30 theoretically reduce ambient noise by 30 dB. 

However, real-world conditions often vary from controlled environments, as variables like fit, movement, and surrounding noise can reduce the effectiveness of hearing protection. To determine the effective noise reduction for real-world applications, use this simple equation:

• Subtract 7 from the NRR
• Divide the result by 2

This provides a more realistic estimate of the expected noise reduction. For example, if a pair of earmuffs has an NRR of 30:

• 30 – 7 = 23
• 23 ÷ 2 = 11.5 dB effective noise reduction

So, in a workspace where noise levels average 95 dB, the worker’s effective exposure would be around 83.5 dB — just under the OSHA action level of 85 dB for an eight-hour shift. Using this formula can help safety managers select hearing protection that fits the actual noise profile of their facility, not just the specs on a box.

Earmuffs are well-suited for environments with intermittent noise or areas with a high degree of sound level variability. © RGtimeline – stock.adobe.com

SELECTING THE RIGHT HEARING PROTECTION FOR THE JOB

To select the appropriate hearing protection for your specific applications, start by monitoring noise levels in specific work environments using sound level meters. While you can use mobile apps for quick assessments, calibrated instruments provide more accurate and OSHA-compliant readings. Measuring noise exposure in various work areas helps determine whether hearing protection is needed and, if so, how much attenuation is required.

Once you understand your facility’s noise profile, you can match hearing protection to the specific demands of the job. Here are some common solutions:

• Earplugs: These are ideal for applications where workers need a lightweight solution that doesn’t interfere with helmets or face shields. Disposable earplugs work well for short-term or single-use needs, while pre-molded reusable options offer more durable and consistent protection. 
• Earmuffs: These are well-suited for environments with intermittent noise or areas with a high degree of sound level variability. Advanced models also come with electronic noise-canceling features, allowing workers to filter out harmful noise while still hearing important communication or alarms. 

For workplaces with extreme noise exposure, dual protection (earplugs plus earmuffs) may be the only way to reduce exposure to acceptable levels. This layered defense is often necessary in environments exceeding 100 dBA.

BEST PRACTICES FOR PROTECTING WORKERS’ HEARING

Even the most advanced safety equipment won’t prevent hearing loss if it isn’t worn correctly and consistently. Improper fit, discomfort, or lack of training on proper use and maintenance can all drastically reduce its effectiveness. 

Earplugs, for instance, require a snug seal inside the ear canal. Workers who don’t roll and insert foam plugs properly may receive only a fraction of the intended protection. Similarly, earmuffs must create a tight seal around the ears, which can be compromised by safety glasses, hard hat straps, or even long hair. 

To address these common challenges, safety managers should:

• Provide a variety of hearing protection options to accommodate different ear and head sizes, shapes, and user preferences. 
• Offer hands-on training during onboarding, including when to replace worn-out or damaged equipment, and reinforce usage in regular safety briefings. Consider conducting hearing tests for new employees to establish a baseline and protect the company from later claims of work-induced hearing loss or tinnitus.
• Encourage workers’ feedback. This can help catch potential discomfort or pressure from their gear. A comfortable fit encourages all-shift wear. When donning hearing protection becomes second nature (and not a nuisance), it’s more likely to be used consistently, even during short or low-noise tasks. 

Noise-induced hearing loss is irreversible — but it’s also entirely preventable. By understanding the risks, choosing the right protection, and promoting a culture of proper use, employers can safeguard one of their workers’ most essential senses and cultivate productivity, well-being, and overall quality of life. WMHS

Rick Pedley, PK Safety’s President and CEO, joined the family business in 1979. PK Safety, a supplier of occupational safety and personal protective equipment, has been operating since 1947 and takes OSHA, ANSI, PPE and CSA work safety equipment seriously. Visit pksafety.com.