Personal protective equipment is the last line of defence between a worker and a hazard, and the lowest control in the WHS hierarchy of controls. If that equipment is cracked, degraded or past its service life, it offers a false sense of security. A quick visual check before every use, backed by documented inspections at set intervals, is what keeps PPE delivering the protection it was designed for.
This guide covers the inspection process for the most common categories of PPE used on Australian worksites: head protection, eye and face protection, hearing protection, hand protection, high-visibility clothing and safety footwear. It sets out what a competent person actually looks for, replacement criteria and the record-keeping the WHS Regulations expect.
Before you start
Gather a PPE inspection checklist, the manufacturer instructions for each item and a pen or digital form. You will also need a clean, well-lit workspace so you can see defects clearly. If you are inspecting fall-arrest harnesses or other height safety gear, refer to the dedicated harness inspection guide: under AS/NZS 1891, a harness used for work above two metres must be inspected by a competent height-safety person at regular intervals, typically every six months, on top of the pre-use check.
Separate the two types of check clearly. Every worker performs a quick visual check of their own PPE before each use. The formal inspections described here are documented checks at regular intervals as part of your safety management system, recorded against each item.
Step-by-step inspection
1. Check labels and certification marks
Every item of PPE must carry the relevant certification marking. In Australia, look for the AS/NZS standard number: AS/NZS 1801 for industrial helmets, AS/NZS 1337.1 for eye protection, AS/NZS 1270 for hearing protectors and AS/NZS 4602.1 for high-visibility garments. Confirm the manufacturing date and any expiry or replacement-by date printed on the item. Imported equipment may instead carry an overseas mark such as CE, UKCA or ANSI, which is only acceptable if it also meets the corresponding AS/NZS requirement. If labels are missing, illegible or the item has no recognised certification, withdraw it from service.
2. Inspect head protection (hard hats)
Examine the shell for cracks, dents, deep scratches, UV degradation (a chalky or flaking surface) and any deformation. Flex the brim gently: a shell that creaks or feels brittle has lost its impact resistance. Turn the hard hat over and inspect the harness cradle for tears, stretching, perishing or broken attachment points, and check the sweatband for deterioration. A hard hat that has taken a heavy impact must be replaced immediately even if no damage is visible. Helmets carry no fixed legal expiry, but most Australian manufacturers specify replacement within three years of first use, or sooner in high-UV outdoor work, which covers most construction and mining sites.
3. Inspect eye and face protection
Examine safety glasses, goggles and face shields for scratches, cracks, chips and discolouration. Scratched lenses reduce clarity and cause eye strain, and a pitted lens will not resist impact as rated. Confirm the marking matches the hazard: medium-impact eyewear is not adequate for grinding or where high-impact protection is required. Check that frames are not bent or loose, side shields are intact, and any goggle seals are still flexible and correctly seated. Replace any item where the lens is compromised or the frame no longer holds the lens securely.
4. Inspect hearing protection
For earmuffs, press the cups together and release: the headband should return firmly to its original position. Inspect the foam cushions for cracks, hardening, tears or flattening, as any of these breaks the seal and lowers the attenuation the class rating promises. For reusable earplugs, check for cracks, hardening, discolouration and loss of flexibility. Single-use plugs are disposed of after each use. If the protector no longer achieves the attenuation needed for the measured noise level, it has failed regardless of its condition.
5. Inspect hand protection (gloves)
Check for cuts, punctures, tears, thinning, chemical degradation, stiffening or loss of grip texture, and confirm the glove still suits the task. For chemical-resistant gloves, roll the cuff to trap air and watch for leaks. For electrical-rated gloves, confirm the test date is within the manufacturer-specified interval before use. Discard any glove that no longer provides its rated level of protection.
6. Inspect high-visibility clothing and safety footwear
For hi-vis garments, check the fluorescent background material for fading, staining or tears, and the retroreflective tape for peeling, cracking or loss of reflectivity. AS/NZS 4602.1 sets separate day-use (Class D), night-use (Class N) and day-and-night (Class D/N) garments, so confirm the garment still meets the class the task calls for, for example day-and-night wear for roadside or low-light work. Faded or peeling garments must be replaced. For safety boots, check sole integrity, toe cap exposure, stitching, lace condition and tread depth. Replace boots once the protective toe cap is exposed or the sole is delaminating.
Replacement criteria by PPE type
Lifespans below are typical manufacturer guidance, not legal limits. Always replace earlier if an item is damaged, has been involved in an incident or no longer meets its AS/NZS class.
| PPE type | Replace when | Typical lifespan |
|---|---|---|
| Hard hat | Cracked, dented, UV-degraded, post-impact, harness damaged | Within 3 years of first use (per manufacturer) |
| Safety glasses | Scratched lens, bent frame, missing side shields | Replace as needed |
| Earmuff cushions | Cracked, hardened, flattened, no longer sealing | Replace when the seal fails |
| Chemical gloves | Punctured, degraded, stiffened, failed leak check | Varies by chemical exposure |
| Hi-vis garment | Faded background, peeling tape, no longer meets its class | Replace when non-compliant |
| Safety boots | Exposed toe cap, sole separation, worn tread | Depends on wear and environment |
PPE register and tracking
A PPE register records every item issued, its type, AS/NZS standard, serial or batch number, issue date, inspection history, condition and replacement date. It is what lets you demonstrate compliance during an audit and track replacement cycles across a workforce. It also surfaces recurring problems, such as one glove type failing early in a particular chemical environment, so you can change the specification rather than keep replacing.
Without a register you have no reliable view of which workers hold current PPE, which items are overdue and whether inspection records are complete. Larger fleets of gear are easier to manage when each item is linked to the worker it was issued to in an asset tracking system, with reminders when an inspection or replacement falls due.
Regulatory requirements
In Australia, the model WHS Regulations set out clear PPE duties for a PCBU. Regulation 44 requires suitable PPE to be provided, regulation 45 requires the PCBU to ensure it is used correctly, and regulation 46 requires it to be maintained, repaired or replaced so it keeps minimising risk. Workers, in turn, must use PPE as instructed and report damage. Safe Work Australia's guidance is explicit that PPE sits at the bottom of the hierarchy of controls: it is used to manage residual risk, not as a substitute for eliminating or engineering out the hazard.
PPE must comply with the relevant AS/NZS standard for its type, and workers must be trained in correct selection, fit and maintenance. If your operation exports work or uses imported equipment, overseas marks (CE or UKCA in the UK and EU, ANSI in the US) may appear on gear, but the Australian benchmark for compliance remains the corresponding AS/NZS standard.
