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When Should You Replace Your Safety Gear?

  • apexwebservices
  • Jun 24
  • 3 min read

A Practical Guide to Timing Workwear Replacement Before It Fails

In industrial environments, safety gear isn’t just part of the uniform—it’s essential protection against serious workplace hazards. But even the best gear doesn’t last forever. Over time, garments wear down, lose their effectiveness, or fall out of compliance with safety standards.


The question is: how do you know when it’s time to replace your safety apparel?

In this guide, we’ll walk through the signs your PPE or safety clothing may no longer be effective, how to create a replacement schedule, and tips for keeping your workforce safe, compliant, and well-equipped.


Why Timely Replacement of Safety Gear Matters

Worn or damaged safety apparel can:

  • Fail to protect workers against burns, impacts, or visibility issues

  • Create a false sense of security

  • Violate HSE or industry regulations

  • Lead to injuries, downtime, and liability claims

  • Damage your reputation with customers and employees

Replacing apparel before it fails ensures your team remains protected and your facility remains compliant and efficient.

Replace your safety gear

General Lifespan Guidelines for Safety Gear

Every garment has a useful life based on usage, laundering, and environment. Here's a general estimate by category:

Apparel Type

Typical Lifespan

FR Shirts & Pants

12–18 months (heavy use)

Hi-Vis Vests & Jackets

6–12 months (or until reflectivity fades)

Coveralls (daily wear)

6–12 months

Rain Gear

1–2 years

Insulated Outerwear

1–3 years

Gloves, Aprons, etc.

Varies by material and use

Note: Always refer to manufacturer guidelines and certifications for accurate lifecycle expectations.


7 Signs It’s Time to Replace Safety Gear

1. Visible Wear and Tear

Look for:

  • Rips, fraying, or open seams

  • Worn cuffs, collars, or waistbands

  • Loose or missing buttons, zippers, or closures

Even small tears can allow hazards (sparks, chemicals) to reach the skin.

2. Faded Colours or Reflective Tape

Hi-vis and branded garments lose effectiveness when:

  • Fluorescent fabric fades (UV damage or washing)

  • Reflective tape cracks, peels, or no longer reflects properly

Once visibility is compromised, the garment no longer meets PPER 2022 requirements.

3. Loss of Flame or Arc Resistance

FR garments that are scorched, contaminated, or over-washed may no longer meet standards.

Common signs:

  • Burn spots

  • Fabric thinning

  • Loss of labelling or arc rating info

✅ Replace if you’re unsure of the garment’s continued protection—visual inspection alone isn’t always enough.

4. Contamination by Hazardous Substances

If garments are exposed to:

  • Flammable chemicals

  • Oils or solvents

  • Biohazards

  • Welding slag or molten metal

…they may no longer be safe to wear, even after washing. Contamination can compromise material integrity and increase risk.

5. Shrinking or Misshaped Garments

Tight, short, or stretched garments reduce:

  • Range of motion

  • Coverage during bending or lifting

  • Overall comfort and compliance

If clothing no longer fits properly, it’s time to replace it.

6. Garment Is Out of Compliance

PPE standards evolve. If a garment:

  • Was made to an outdated standard, or

  • Labelling is missing or unreadable 

…it may not meet current compliance requirements. That alone is grounds for replacement.

7. Repeated Laundering Wear

Frequent washing, especially with industrial detergents, gradually:

  • Wears down fabric integrity

  • Dulls reflective surfaces

  • Weakens seams or stitching

Track wash cycles or establish a number-of-washes policy (e.g., replace after 50–100 washes, depending on fabric and care instructions).


How to Build a Workwear Replacement Schedule

Use a proactive approach instead of waiting for clothing to fail.

1. Establish Replacement Intervals by Role

Some workers wear their gear harder than others. For example:

  • Daily welders may need new coveralls every 6 months

  • Warehouse associates may need new hi-vis vests every 12 months

  • Electrical maintenance techs may need new arc-rated gear annually

2. Document Issue and Inspection Dates

Track gear distribution and inspections using:

  • A spreadsheet

  • Uniform management software

  • Tags or QR-coded labels on garments

3. Train Workers to Self-Inspect

Give employees a simple checklist for weekly or monthly inspections (e.g., tears, reflectivity, comfort, compliance labelling).

Common Mistakes to Avoid

Mistake

Why It’s Risky

What to Do Instead

Waiting for a garment to “fail”

May already be non-compliant or unsafe

Replace on a schedule or at first sign of wear

Reissuing used gear to new hires

May be improperly sized or degraded

Start each worker with properly fitted PPE

Failing to train on care & washing

Accelerates wear, reduces protection

Provide clear care instructions

Ignoring manufacturer guidance

May void certification or warranty

Always follow original product guidance

Final Thoughts: Safety Gear Only Works If It Works

Your team’s safety apparel is only effective if it fits, performs, and protects as intended. Replacing worn or non-compliant garments before they fail is a simple but powerful way to reduce risk, maintain compliance, and show your team that their safety matters.

Need help managing a uniform replacement program or sourcing safety-rated apparel that lasts? We can provide issue tracking, job-specific wear kits, and reminders based on your team’s usage. [Contact us today] to build a replacement plan that fits your operation.

 
 
 

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