Personal Protective Equipment (PPE) is only as effective as its condition. Even the best gloves, helmets, and respirators lose protection over time. Cracks, fading, worn straps, or contaminated filters can make gear useless — sometimes without workers realizing it.
According to OSHA 29 CFR 1910.132, employers are required to inspect, maintain, and replace PPE whenever it becomes damaged or no longer provides adequate protection. Neglecting PPE upkeep can result in OSHA citations, serious injuries, or fatalities.
This guide provides a complete PPE inspection and replacement checklist for 2025, explaining how often to replace each type of safety gear — and how to stay OSHA and ANSI compliant.
1. Why PPE Inspection and Replacement Matter
Even high-quality PPE has a lifespan. Materials degrade, components fail, and protective ratings diminish over time. A glove with a small tear or a respirator with a cracked seal can make the difference between full protection and injury.
OSHA 1910.132(a) clearly states:
“Protective equipment... shall be maintained in a sanitary and reliable condition.”
Employers must not only supply PPE but ensure it’s inspected and replaced before it fails.
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2. OSHA Requirements for PPE Maintenance
OSHA doesn’t specify exact replacement dates for all PPE but requires that each item be maintained, inspected, and replaced as necessary. Employers must:
- Provide PPE appropriate to workplace hazards.
- Train workers on inspection and maintenance procedures.
- Replace PPE immediately when it’s defective or contaminated.
- Keep records of PPE issuance and replacement cycles.
ANSI standards — like ANSI Z89.1 (hard hats) and ANSI/ISEA 105 (gloves) — offer guidance on lifespan and inspection intervals.
3. PPE Inspection and Replacement Checklist by Category
Let’s break down inspection steps and replacement timelines for common PPE categories.
A. Hand Protection (Gloves)
Applicable Standard: OSHA 1910.138 and ANSI/ISEA 105-2020
Inspection Checklist:
- Look for cracks, tears, cuts, and discoloration.
- Stretch gloves to check for hidden pinholes.
- Check chemical gloves for swelling, stickiness, or stiffness.
- Verify labeling and manufacturer markings.
Replacement Frequency:
- Disposable nitrile/latex gloves: Every use.
- Cut-resistant or coated gloves: Every 3–6 months or when coating wears off.
- Chemical-resistant gloves: After contamination or chemical exposure.
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B. Eye and Face Protection (Safety Glasses, Goggles, Shields)
Applicable Standard: OSHA 1910.133 and ANSI Z87.1
Inspection Checklist:
- Examine lenses for scratches, cracks, or cloudiness.
- Check frame and strap integrity.
- Confirm anti-fog or coating layers aren’t peeling.
Replacement Frequency:
- Every 6–12 months, or sooner if scratched or distorted.
- Immediately if dropped, cracked, or contaminated.
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C. Head Protection (Hard Hats, Bump Caps)
Applicable Standard: OSHA 1910.135 and ANSI Z89.1
Inspection Checklist:
- Inspect shell for cracks, dents, fading, or chalkiness.
- Check suspension straps for fraying or dry rot.
- Examine date stamp inside the shell.
Replacement Frequency:
- Shell: Every 5 years (max) or after impact.
- Suspension: Every 12 months.
- Replace immediately if dropped from height or hit by falling objects.
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D. Hearing Protection (Earplugs & Earmuffs)
Applicable Standard: OSHA 1910.95
Inspection Checklist:
- Check earplugs for dirt, tears, or hardened surfaces.
- Inspect earmuff cushions for cracks or flattening.
- Confirm NRR (Noise Reduction Rating) labeling is legible.
Replacement Frequency:
- Disposable foam plugs: After every use.
- Reusable plugs: Every 2–4 weeks.
- Earmuff cushions: Every 6 months (replace cushions & foam inserts).
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E. Respiratory Protection
Applicable Standard: OSHA 1910.134
Inspection Checklist:
- Check facepiece for cracks, tears, or distorted seals.
- Inspect straps and valves for elasticity.
- Verify filters and cartridges are clean and dry.
Replacement Frequency:
- Disposable N95 respirators: After one use or when breathing resistance increases.
- Half/full-face respirators: Inspect before each use; replace if seal fails.
- Filters/cartridges: As per manufacturer schedule or when odor/taste is detected.
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F. High-Visibility Apparel (Vests, Jackets, Rain Gear)
Applicable Standard: ANSI/ISEA 107-2020
Inspection Checklist:
- Look for fading, dirt, and reflective tape wear.
- Check stitching and closures.
- Confirm visibility at distance in daylight and headlights.
Replacement Frequency:
- Every 6–12 months or after ~25 wash cycles.
- Immediately if reflective tape loses brightness or peels.
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G. Foot Protection (Safety Boots, Overshoes)
Applicable Standard: OSHA 1910.136 and ASTM F2413
Inspection Checklist:
- Inspect soles for separation, cracks, and oil deterioration.
- Check steel/composite toe for dents or deformation.
- Inspect inner lining for moisture or odor.
Replacement Frequency:
- Every 12–18 months, or sooner if punctured or leaking.
H. Fall Protection (Harnesses, Lanyards, Lifelines)
Applicable Standard: OSHA 1926.502 and ANSI Z359
Inspection Checklist:
- Look for frayed webbing, corrosion, missing stitching, or deformities.
- Check D-rings and snap hooks for cracks or sharp edges.
Replacement Frequency:
- Every 5 years, or immediately after a fall or inspection failure.
4. Common Mistakes in PPE Replacement
- Waiting until visible damage occurs. Microscopic cracks and UV degradation can reduce protection long before failure.
- Ignoring expiration dates. Many PPE types have stamped manufacture dates and replacement timelines.
- Improper cleaning. Harsh detergents or heat drying can damage coatings and reflective materials.
- Reusing disposables. Single-use means one task — reusing disposable gloves or respirators increases contamination risk.
- No recordkeeping. Tracking PPE inspections and replacements ensures accountability and OSHA compliance.
5. Creating a PPE Inspection Program
An effective inspection and replacement program should include:
- Daily user checks – Before each shift.
- Monthly supervisor audits – Spot checks on PPE condition.
- Annual full evaluations – Replace aging or obsolete gear.
- PPE inventory log – Track issue dates, employee assignments, and replacements.
OSHA encourages employers to build a documented PPE maintenance program that includes written policies, inspection logs, and worker retraining when required.
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6. The Bottom Line
Your PPE program is only as strong as your inspection schedule. Outdated gloves, faded vests, or expired respirators give workers a false sense of security — and that’s when injuries happen.
Make PPE inspection and replacement a daily habit, not a yearly checklist.
When in doubt, replace it. Safety is cheaper than an accident.
People Also Ask (FAQ)
1. How often should PPE be replaced?
Replace PPE as soon as it shows damage, contamination, or wear. Hard hats every 5 years, safety vests every 6–12 months, and disposable gloves or respirators after each use.
2. Do PPE items expire?
Yes. Most PPE has a manufacturer date and shelf life (e.g., hard hats, respirators, chemical gloves). Always follow manufacturer and ANSI guidance.
3. Who is responsible for PPE inspection?
Employers must inspect PPE regularly, but workers must also perform daily self-checks before using gear.
4. What is the most commonly overlooked PPE replacement?
Suspension straps in hard hats and reflective vests after washing. These wear out long before the outer shell.
5. Can worn PPE still be used for training?
No. Old or defective PPE should be removed from service to prevent accidental reuse.
Author Bio
Mick Chan is a Safety Supplies industry professional with over 15 years of hands-on experience. He specializes in OSHA compliance, PPE regulations, and bulk safety product procurement for high-risk industries. Mick earned his Bachelor’s degree in Business Administration from Cal State LA in 2013 and has been advising companies across California ever since. Born and raised in the San Gabriel Valley, he understands the safety needs of businesses in diverse urban and industrial environments. His work focuses on bridging safety compliance with practical product solutions for the modern workplace.