Why We Need to Revisit Hearing-Loss Prevention for Factory Workers

What the research reveals about the larger trends and tactics.

Noise-linked hearing loss is the most common work-related injury, with 22 million workers—about 17 percent of the labor force—exposed to hazardous decibel levels on the job, according to researchers at the National Institute for Occupational Safety and Health (NIOSH).

NIOSH researchers define hearing loss as “difficulty hearing another person talking, even in a quiet place or on the phone.” One in eight noise-exposed workers suffers some form of hearing loss, a recent study found.

Excessive noise is a threat to both employee safety and productivity, resulting in repetitive or misunderstood workplace conversations and health risks. “Our whole body responds to noise, not just our ears,” says Marjorie McCullagh, Ph.D., a professor at the University of Michigan School of Nursing with a research specialty in hearing loss. “Noise exposure impacts our blood pressure, stress levels and risks for headache, fatigue and cardiovascular events.”

Different Industries, Different Ear Safety Concerns

Workers in the mining, construction and manufacturing sectors are especially prone to noise-linked hearing loss, according to the research, even though noise exposure in mining and manufacturing has been regulated for decades.

The Occupational Safety and Health Administration (OSHA) requires implementation of a hearing-conservation program for workers exposed to an eight-hour sound level of 85 or more A-weighted decibels, a measure of the relative loudness of sound as perceived by the human ear. For example, the sound level of a power lawnmower, in comparison, equals 106 decibels.

Workers in nonindustrial settings including healthcare, real estate and finance are at risk for hearing loss due to excessive noise, the study found. These are industries in which hearing loss is not commonly thought of as a challenge, outcomes that surprised lead researcher Elizabeth Masterson, Ph.D., and her NIOSH colleagues. As a result, she says, “our message is every industry has exposed workers and needs to make hearing conservation a priority.”

Think Prevention First

Masterson and her team stress that most workplace ear damage can be prevented; all the more important since hearing loss is permanent.

OSHA allows employers to rely on a combination of prevention strategies to dial down the decibels. Administrative controls reduce or eliminate worker exposure to noise, such as limiting the amount of time a worker spends at a noise source. Engineering controls include isolating the noise source or placing barriers like sound walls.

Ear protection to block or reduce noise is another option, although less desirable, says McCullagh, because it depends on employee compliance.

Tips for Ear Protection and Hearing-Loss Prevention

“One size doesn’t fit all” applies when it comes to the four most common styles of ear protection available, McCullagh says. “The goal is to knock down the noise to a safe level. You want to be able to hear machines and people talking to you, be aware of other things in your environment and not feel cut off from the world.”

She describes these common options:

• Compressible foam plugs, though soft and comfortable, can end up irritating the ear canal if taken in and out all day to protect against intermittent noise.
• Premolded earplugs with rigid stems are less comfortable but are good for dirty work environments because workers’ fingers come into contact with only the stem.
• Earmuffs, which cover the ear completely and are an easy fit, don’t work well for those wearing eyeglasses or eye protection because they can’t maintain a seal against the head.
• Canal caps are like modern headsets, with small foam cushions that rest just outside the ear canal and attach to a plastic band that can be worn over the head or under the chin. These provide the most comfort and adequate protection.

Your Bottom Line Will Thank You

An estimated $242 million is spent annually in workers’ compensation claims alone for hearing loss. That figure doesn’t include medical or personal costs, which could more than double the true financial impact. “Awareness and allocating resources for hearing-loss prevention is the key,” Masterson says.

What are your favorite ear-protection products and why?