Personal protective equipment is the last line of defence between a worker and a hazard. If that equipment is cracked, degraded or past its service life, it offers a false sense of security. Regular inspection before every use, and formal documented inspections at set intervals, ensures PPE actually delivers the protection it was designed for.
This guide covers the inspection process for the most common categories of PPE used on worksites: head protection, eye and face protection, hearing protection, hand protection, high-visibility clothing and safety footwear. It includes replacement criteria, record-keeping requirements and references to Australian, US and UK standards.
Before you start
Gather a PPE inspection checklist, the manufacturer guidelines for each item and a pen or digital form. You will also need a clean, well-lit workspace so you can see defects clearly. If you are inspecting fall-arrest harnesses, refer to the dedicated harness inspection guide for the detailed procedure.
Every worker should perform a quick visual check of their own PPE before each use. The formal inspections described in this guide are documented checks conducted at regular intervals as part of your safety management system.
Step-by-step inspection
1. Check labels and certification marks
Every item of PPE must carry the relevant certification marking. In Australia, look for the AS/NZS standard number (e.g. AS/NZS 1801 for hard hats, AS/NZS 1337.1 for eye protection). In the US, look for ANSI ratings. In the EU and UK, the CE or UKCA mark applies. Check the manufacturing date and any expiry or replacement-by date printed on the item. If labels are missing, illegible or the item has no certification marking, withdraw it from service.
2. Inspect head protection (hard hats)
Examine the shell for cracks, dents, deep scratches, UV degradation (chalky or flaking surface) and any deformation. Turn the hard hat over and inspect the harness cradle for tears, stretching, perishing or broken attachment points. Check the sweatband for deterioration. Hard hats that have sustained a heavy impact must be replaced immediately, even if no visible damage is present. Most manufacturers recommend replacement every 3 to 5 years depending on exposure conditions.
3. Inspect eye and face protection
Examine safety glasses, goggles and face shields for scratches, cracks, chips and discolouration of the lens. Scratched lenses reduce clarity and can cause eye strain. Check that frames are not bent or loose, that side shields are intact and that any seals (on goggles) are still flexible and seated correctly. Replace any item where the lens is compromised or the frame no longer holds the lens securely.
4. Inspect hearing protection
For earmuffs, check headband tension by pressing the cups together and releasing. The band should return to its original position firmly. Inspect foam cushions for cracks, hardening, tears or flattening. Cracked or flattened cushions reduce the noise reduction rating (NRR) and must be replaced. For reusable earplugs, check for cracks, hardening, discolouration and loss of flexibility. Single-use plugs must be disposed of after each use.
5. Inspect hand protection (gloves)
Check for cuts, punctures, tears, thinning, chemical degradation, stiffening or loss of grip texture. For chemical-resistant gloves, inflate slightly by rolling the cuff and trapping air, then check for leaks. For electrical-rated gloves, confirm the test date is within the manufacturer-specified interval. Discard any gloves that no longer provide the rated level of protection.
6. Inspect high-visibility clothing and safety footwear
For hi-vis garments, check background fluorescent material for fading, staining or tears. Inspect retroreflective tape for peeling, cracking or loss of reflectivity. Garments that no longer meet the minimum visible area requirements of AS/NZS 4602.1 (or ANSI/ISEA 107 in the US) must be replaced. For safety boots, check sole integrity, toe cap exposure, stitching, lace condition and tread depth. Replace boots when the protective toe cap is exposed or the sole is delaminating.
Replacement criteria by PPE type
| PPE type | Replace when | Typical lifespan |
|---|---|---|
| Hard hat | Cracked, dented, UV-degraded, post-impact, harness damaged | 3 to 5 years |
| Safety glasses | Scratched lens, bent frame, missing side shields | Replace as needed |
| Earmuff cushions | Cracked, hardened, flattened, no longer sealing | 6 to 12 months |
| Chemical gloves | Punctured, degraded, stiffened, failed leak test | Varies by chemical exposure |
| Hi-vis vest | Faded fluorescent material, peeling tape, torn | Replace when non-compliant |
| Safety boots | Exposed toe cap, sole separation, worn tread | 6 to 24 months depending on use |
PPE register and tracking
A PPE register records every item issued, its type, standard, serial or batch number, issue date, inspection history, condition and replacement date. This register is essential for demonstrating compliance during audits and for tracking replacement cycles across your workforce. It also helps you identify recurring issues, such as a particular glove brand failing prematurely in a specific chemical environment.
Without a register, you have no visibility of which workers have current PPE, which items are overdue for replacement and whether inspection records are complete. An asset tracking system makes this manageable at scale by linking each item of PPE to the worker it was issued to, with automated reminders when inspections or replacements are due.
Regulatory requirements
In Australia, the WHS Regulations (Part 3.2) require PCBUs to provide and maintain PPE that is suitable for the nature of the work and any identified hazard. PPE must comply with the relevant AS/NZS standard. Workers must be trained in the correct use, fit and maintenance of their PPE. Key standards include AS/NZS 1801 (head protection), AS/NZS 1337.1 (eye protection), AS/NZS 1270 (hearing protectors) and AS/NZS 4602.1 (high-visibility clothing).
In the US, OSHA 29 CFR 1910 Subpart I covers general PPE requirements, including hazard assessment, selection, training and maintenance. Employers must assess the workplace to determine hazards, select appropriate PPE that meets ANSI standards and ensure workers are trained in its use. OSHA standards for specific PPE include 1910.135 (head protection), 1910.133 (eye and face protection) and 1910.138 (hand protection).
In the UK and EU, the Personal Protective Equipment at Work Regulations 2022 (UK) and EU Regulation 2016/425 set requirements for PPE provision, assessment, maintenance and training. PPE must be CE or UKCA marked and suitable for the identified risks.
Going digital with MapTrack
Tracking PPE inspections on paper or spreadsheets works for a small crew, but breaks down once you have dozens of workers across multiple sites. MapTrack lets you build a digital PPE register using asset tracking, linking each item to the worker it was issued to. When an inspection is due or a replacement date approaches, the system sends automated alerts so nothing is missed.
Use digital inspection forms to standardise PPE checks across all sites. Inspectors capture photos of defects, record pass/fail results and raise replacement requests in one workflow. All records feed into your compliance dashboard, giving safety managers a real-time view of PPE status across the organisation and a complete audit trail for regulators.
