How Often Should PPE Be Replaced?

Date Posted:21 August 2025

PPE doesn’t last forever. From hard hats to harnesses, safety gear has expiry dates and signs of wear. Learn when to replace PPE to protect your staff and stay WHS compliant.

Why Replacing PPE Matters

Personal Protective Equipment (PPE) is a vital safeguard in any workplace—but it doesn’t last forever. Over time, even the most durable PPE can degrade, expire, or become damaged through regular use.

Continuing to use worn-out or faulty PPE increases the risk of injury, reduces compliance with Work Health and Safety (WHS) regulations, and may expose employers to liability. Under WHS laws, employers have a duty of care to provide effective, well-maintained PPE that offers adequate protection.

At Verdex, we believe it is an important Knowing when to replace PPE clothing and safety gear isn’t just good practice—it’s a legal and ethical responsibility that helps keep workers safe and businesses compliant.

Factors That Affect PPE Lifespan

Type of Material

Some PPE is made for single use (like disposable nitrile gloves), while others are built for long-term wear (like leather gloves or steel-toe boots). Durable items tend to last longer but still require regular checks for wear and tear.

Frequency of Use

Items used daily—such as hi-vis clothing, hearing protection, and safety glasses—wear out faster than PPE used only occasionally (like fall arrest gear). The more an item is used, the more frequently it needs replacing.

Environmental Conditions

Harsh conditions accelerate wear. Exposure to heat, moisture, chemicals, or UV light can weaken PPE materials over time. For example, a hard hat left in direct sunlight will deteriorate faster than one stored properly.

Storage & Maintenance

Proper care makes a big difference. PPE kept in wet, dusty, or poorly ventilated spaces will degrade faster. Clean, dry storage areas and regular maintenance extend lifespan and effectiveness.

PPE Replacement Guidelines by Category

To stay compliant and safe, here’s a breakdown of typical replacement timelines and red flags across common PPE types.

Eye & Face Protection

Replace if lenses are scratched, cracked, or frames are loose.
Fogging or seal failures also indicate it’s time to update.
General guideline: Replace every 6–12 months, or immediately if damaged.

Respiratory Protection

Disposable masks (e.g. P2 dust masks): Single-use only.
Reusable respirators: Replace filters after the specified usage hours or when breathing resistance increases.
Replace full mask if it’s cracked, deformed, or hygiene cannot be maintained.

Head Protection (Hard Hats)

Must comply with AS/NZS 1801.
Replace every 2–3 years, or immediately after a significant impact or if visible cracking appears.
UV exposure also weakens the shell—check colour fading as a sign.

Hand Protection (Gloves)

Disposable gloves: One-time use.
Reusable gloves: Replace when punctured, degraded, or visibly worn—especially if used with chemicals or sharp tools.

Footwear

Replace every 6–12 months depending on usage.
Signs it’s time: Worn soles, exposed toe caps, torn stitching, or loss of grip.
Ensure footwear still meets AS/NZS 2210.3.

Hi-Vis Clothing

Replace if faded, torn, or reflective strips are peeling off.
Visibility is critical for safety, especially near machinery or vehicles.
Lifespan: Typically 6–12 months with regular washing.

Hearing Protection

Earplugs: Disposable (daily), reusable (check packaging).
Earmuffs: Inspect seal cushions regularly. Replace pads every 6 months or if the seal is compromised.

Fall Protection (Harnesses & Lanyards)

Follow manufacturer instructions and industry standards.
Replace every 5 years, or immediately if damaged.
Must be inspected every 6 months, especially in high-risk industries like construction or roofing.

Signs It’s Time to Replace Your PPE

Knowing when PPE needs replacing can prevent injuries before they happen. Watch out for:

Tears, cracks, or visible damage
Loose or degraded fit reducing comfort or safety
Faded hi-vis fabric or unreadable labels
Expired dates on PPE such as respirators or harnesses
Increased complaints or near misses from staff
Failed inspections or functional tests

Encouraging workers to report faulty PPE helps maintain a proactive safety culture.

Australian Standards for PPE Replacement

In Australia, PPE must meet specific AS/NZS standards, many of which also provide guidance on inspection and replacement:

AS/NZS 1337: Eye and face protection
AS/NZS 1801: Industrial safety helmets
AS/NZS 2210.3: Occupational protective footwear
AS/NZS 1715 & 1716: Respiratory protective devices

Beyond meeting initial compliance, employers must ensure PPE remains suitable throughout its use. That means regular inspections, proper care, and timely replacement based on wear or industry guidelines.

To support compliance, businesses should also consider complementary safety measures with workplace safety equipment and supplies.

These include safety barriers and security bollards, workplace first aid equipment, and workplace safety signage and information—all of which play a vital role in creating a safer, more compliant work environment.

Managing PPE Replacements Effectively

To stay on top of PPE replacement schedules and ensure nothing slips through the cracks:

Set reminders for inspections and expiry dates
Maintain a PPE register or checklist
Conduct monthly PPE inspections
Train staff to spot signs of wear or expiry
Partner with trusted suppliers like Verdex for reliable stock and expert support

Proactive PPE management not only keeps your team safe but also supports compliance during WHS audits and inspections.

Reach Out To Us About PPE Safety Gear

PPE is only as effective as its condition allows. Understanding when and why to replace protective gear helps maintain a safe, compliant, and productive workplace. With clear processes and support from trusted suppliers like Verdex, staying on top of PPE maintenance is easier than ever. Get in touch with us today.

Call our toll-free number 1800 750 500
Email our team at sales@verdex.com.au
Fill out our contact form online

Frequently Asked Questions

How do I know when PPE should be replaced?

Look for visible damage, fading, loss of fit, or signs of wear. Follow manufacturer guidelines and conduct regular inspections to ensure gear remains effective.

Can I still use PPE past its expiry date if it looks fine?

No. Expiry dates indicate the safe working life of PPE. Using expired equipment can result in failure during use and may breach WHS laws.

Is PPE lifespan the same across all industries?

No. High-risk industries like mining or chemical handling may require more frequent replacement due to harsher environments and more intense use.

What records should I keep for PPE replacement?

Maintain a PPE register including item type, issue date, expiry date, inspection history, and replacement schedule. This helps ensure compliance and traceability.

Does Verdex offer advice or product recommendations?

Yes. Verdex offers expert advice and a wide range of compliant, quality-assured PPE. Our team can help you choose the right gear and build a replacement plan.

How Often Should PPE Be Replaced?

Why Replacing PPE Matters