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.

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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