Knowing when to replace PPE and workwear matters, because worn-out kit doesn't just look tired, it stops protecting. Faded hi-vis, smooth boot soles and gloves with worn-through coatings can all look usable while no longer doing their job. Here are five signs it's time for replacements, and how to stay ahead of them.

Signs of wear on hi-vis and safety boots

1. Faded hi-vis and damaged reflective tape

Fluorescent fabric loses its brightness with washing and UV exposure. If your yellow vest looks pale lemon, it may no longer meet EN ISO 20471, the standard for high-visibility clothing. Cracked, peeling or dirty reflective tape is an instant fail too.

Check the care label as well. Many hi-vis garments state a maximum number of wash cycles, and beyond that the manufacturer can't vouch for the performance. New hi-vis vests cost little compared with the risk of not being seen, and our guide to hi-vis classes explains which level you need.

2. Worn boot soles and damaged toe caps

Slip resistance depends on tread depth, so smooth patches mean grip is gone. Check for exposed or dented toe caps, splitting uppers and leaking seams. A boot that's taken a heavy impact should be replaced even if it looks fine, as the toe cap may be compromised.

Look underneath too. A nail or screw that has gone through the sole can damage a penetration-resistant midsole, and a sole coming away from the upper lets in water and debris. When you buy new safety boots, match the rating to the job: S3 for most outdoor site work, for example, with the optional SR marking if floors are often wet or oily.

Damaged garments and tired branding

3. Rips, failed zips and missing fastenings

Torn garments snag on machinery and let weather in, while a jacket that won't fasten can't do its job. Minor repairs are fine; structural damage isn't.

A useful rule is to replace anything where the damage affects protection or fit. A missing button on a polo is cosmetic. A split seam in waterproof trousers, a broken zip on a coverall worn near moving parts, or a torn kneepad pocket are not. Kneepad inserts to EN 14404 are certified with the trouser they sit in, so a damaged pocket is a safety issue.

4. Illegible branding

Cracked prints and unravelling embroidery send the wrong message to customers. Your uniform is your shop window, so keep it presentable.

Faded logos usually come from washing too hot or tumble drying printed garments. Turning items inside out and following the care label helps, but once a logo is patchy it's time to reorder.

Expired or damaged PPE

Hard hats have recommended replacement dates, gloves lose their rated protection once coatings wear through, and respirator seals degrade. If in doubt, swap it out.

• Helmets: follow the manufacturer's guidance on service life, and replace any safety helmet that has taken a significant blow or shows cracks, chalky fading or a damaged harness.
• Gloves: work gloves rated to EN 388 lose their cut and abrasion performance once the coating is worn or holed.
• Masks: disposable masks marked NR are for a single shift only, and reusable masks need filters and seals checked against the maker's instructions.

Under the PPE at Work Regulations 1992, employers must provide PPE free of charge and keep it in good repair, which includes replacing it. Since 6 April 2022 this duty also extends to most casual and agency-type workers.

How often should you check workwear and PPE?

A quick quarterly kit inspection catches most issues before they become risks, and budgeting for rolling replacement beats emergency buying every time. Alongside it, ask staff to check PPE before each use and report damage straight away. A simple record of issue dates shows which items wear fastest.

Quick answers

How often should hi-vis be replaced?

There's no fixed date. Replace hi-vis when the fluorescent colour has faded, the reflective tape is cracked, peeling or dirty, or it has gone past the maximum number of washes on the care label.

How long do safety boots last?

It depends on the work and how often they're worn. Replace them when the tread is worn smooth, the toe cap is exposed or has taken a heavy impact, or the uppers and seams are splitting.

Who pays for replacement PPE?

The employer. Under the PPE at Work Regulations 1992, PPE must be provided free of charge and kept in good repair, and since 6 April 2022 this duty also covers most casual and agency-type workers.

Ready for a refresh? Browse our PPE range to replace like-for-like or upgrade your team's kit, or get in touch for help matching ratings to your risk assessment.