HOW LONG DOES PPE LAST?

The Personal Protective Equipment (PPE) at Work Regulations 1992 put legal duties on employers to ensure that PPE is:

• Used correctly by everyone
• Issued with clear instructions
• Maintained and stored properly
• Fully assessed to make sure it’s fit for purpose

But did you know that PPE also has an expiry date?

Hard hats, work boots, ear defenders - all PPE eventually expires. 

Once past its shelf life, PPE isn’t just ineffective - it’s as dangerous as wearing none at all. Knowing your expiry dates is key to protecting your team and staying compliant.

In this blog, we explain when, why, and how to replace your PPE.

HOW TO CHECK THE PPE EXPIRY DATE

Every piece of PPE either has an expiry date or a recommended replacement schedule.

Now, for the fine print - just because a hard hat’s expiry date is five years away, doesn’t mean you can use it for five years.

The PPE expiry date only suggests the maximum lifespan.

It doesn’t factor in:

• Damage 
• Poor storage 
• Wear and tear
• Replacement dates
  

HOW TO FIND YOUR PPE EXPIRATION DATE 

Where to look:

• Look for a label with an expiry date or recommended service life.
• No label? Check the manual or get in touch with the supplier.

TOP TIP: Don’t forget about the recommended storage time before use - it gives you less time to use your PPE.

HOW TO CHECK IF PPE IS SAFE TO USE

Inspect labels, expiry dates, and manufacturer instructions. But, there’s more to it than that.

Here’s a quick checklist:

• Check the fit - make sure your PPE fits well with no gaps, slipping, or pain points.
• Know the shelf life - PPE breaks down at different rates, so always check its expiry date.
• Check it’s working - especially for electrical or mechanical PPE like respirators or harnesses.
• Look it over - check your PPE for cracks, tears, scratches, warping, brittle straps, or anything else that looks off.

If it looks worn out or if you’re in any way unsure, replace your Personal Protective Equipment.

WHY UP-TO-DATE PPE MATTERS

Outdated PPE is unsafe PPE - it puts your workforce at risk and your business at risk of non-compliance.

1. SAFETY FIRST

Nothing lasts forever - even the toughest PPE materials break down with time and use.

When it does, it can’t shield you or others from workplace hazards.

Watch out for common failure points:

• Filters clog
• Gloves split
• Helmets crack
• Soles wear smooth

2. LEGAL COMPLIANCE

Under PPER 1992, employers must supply, identify, and maintain the correct PPE when risks can’t be controlled by other means. 

Out-of-date PPE could result in fines or legal consequences if an incident occurs.

3. HEALTH AND WELL-BEING

Old PPE doesn’t just stop working - it can cause serious health issues.

For example:

• Worn-out boots with no grip lead to slips, trips, and falls.
• Clogged respiratory filters can’t filter out harmful particles.
• Weakened safety shields or goggles can’t protect the eyes from chemicals or debris.

HOW OFTEN TO REPLACE PPE

Expiry dates on your products assume perfect storage and light use. If your PPE is used daily, it may need to be replaced much sooner.

Replace your PPE if it’s:

• Damaged, cracked, warped, or scratched
• No longer performing as it should or fit for purpose
• Dirty beyond cleaning or visibly worn (especially Hi-vis)
• Affected by excessive sunlight, moisture, chemicals, or extreme temperatures

And always:

• Never use your PPE past the maximum shelf life, even if it looks ok.
• Regularly clean and properly store your PPE gear to extend its lifespan.
• Throw away disposable PPE (earplugs, dust masks, gloves) after each use.

HOW TO REPLACE PPE ON-SITE

Follow these simple steps:

1. Identify any expired or damaged PPE
2. Remove it safely to avoid contamination
3. Order all PPE replacements
4. Log order for safety records and compliance
5. Inspect your new PPE for flaws and correct sizing
6. Try on your new PPE - make sure it fits

HOW LONG DOES PPE LAST?

How long your PPE lasts depends on things like: 

• How much use does it get?
• What type of product is it?
• How well is the item looked after?

HARD HATS AND SAFETY HELMETS

Here’s what you need to know:

• Hard hats and safety helmets can last up to five years if unused and stored properly.
• They expire sooner in real-life working conditions. 
• Replace your hard hat every 2-3 years, even if it looks fine.

Signs your hard hat needs to be replaced:

• Cracks, splits, fading
• Worn or brittle suspension straps
• Flaking or chalky texture from UV damage

TOP TIP: Wash your hard hat daily and let it air dry, especially if it’s exposed to chemicals and sun exposure.

SAFETY BOOTS

Safety boots work hard:

• Soles wear
• Steel-toes show
• Support reduces 

How long your boots last depends on how you use them:

• Worn all day long - boots can burn out in three to six months.
• Used lightly and well-maintained, boots can last one to two years.

HI-VIS CLOTHING

The important stuff:

• Hi-vis PPE typically lasts no more than six months. 
• Excessive wear or washing can lead to poor visibility and accidents.

Signs it’s time to replace your Hi-vis:

• Tears or heavy staining
• Dull colours or faded patches
• Damage from heat or chemicals
• Cracked or peeling reflective tape

TOP TIP: Hi-vis clothing can only be washed about 25 times before it stops reflecting light. 

GOGGLES AND SAFETY GLASSES

You’ve heard the saying - foresight is better than no sight:

• Goggles and safety glasses can last up to three years.
• But you’ll usually need to replace them before then.
• Know when to replace your safety glasses - it could save your sight.

Watch out for:

• Dust and debris beyond cleaning
• Uncomfortable or loose-fitting lenses
• Scratched lenses and reduced visibility

TOP TIP: Check your safety glasses and goggles are in good working order daily.

EAR PROTECTION

If you’re wondering, ‘Do ear defenders have an expiry date?’ - yes, they do.

• Over-ear defenders last about two to three years.
• However, this lifespan doesn’t account for wear and tear.

Watch out for:

• A loose seal 
• Worn cushions
• Worn headbands

HOW OFTEN SHOULD PPE BE INSPECTED?

How often you check your PPE depends on the PPE type, level of use, and workplace.

That said, you can keep it simple with our guide:

• Daily - briefly check for wear, cracks, or missing parts.
• Monthly - thoroughly inspect for any damage or a loose fit.
• Yearly - fully review or formally inspect all your PPE on-site.

Also, re-assess PPE when:

• Equipment changes
• A new hazard appears
• Regulations are updated
• An incident occurs at work

If your PPE looks or feels off at all, replace it. PPE only works if it’s in good working order.

PPE MAINTENANCE TIPS

PPE can wear out well before its expiration date. The good news is, you can extend its life with a few simple tricks.

Follow these simple PPE maintenance tips:

• Schedule annual inspections
• Train your team on storage and daily checks
• Keep records of replacements and expiry dates
• Clean gear using the manufacturer’s recommendations
• Store PPE in a cool, dry place away from chemicals or sunlight

PPE can only defend against injury and infection when it is in the right condition.

Need some help sorting your gear?

Drop us a message, or give us a call on 0330 441 3500.

FAQs

Want the answers to the most commonly asked questions about PPE?

HOW LONG DOES ARC FLASH CLOTHING LAST?

It’s best to replace your ARC flash clothing every 5 years, or before 50 washes (whichever comes first). Replace the item sooner if it’s torn, faded, or the label is unreadable.

CAN YOU REUSE PPE?

Some types can be reused. Single-use PPE (dust masks, earplugs, safety gloves) must be discarded after use. Reusable PPE must always be inspected and in good condition.

WHERE IS THE EXPIRY DATE ON A HARD HAT?

It’s usually inside the shell. Look for a clock symbol showing the year in the centre, and an arrow pointing to the month it was made. Once you know the manufacturer date, you count forward five years. 

HOW OFTEN SHOULD PPE BE REVALUED?

Reassess when tasks, risks, or environments change and continually review your full site annually.

HOW DO YOU REPLACE PPE?

Replacing PPE should be fast, easy, and on budget. 

At SMI, we take the guesswork out of PPE. We know what works, and we’ll help you find it.

Here’s how we make it easy:

• 97% stock availability
• Maximum 3-hour response time
• 2-day dispatch on branded garments
• 5PM order cut-off for next day delivery
• Own delivery fleet in key regions for extra reliability

With SMI, you’re partnering with a team dedicated to protecting your people.

NEED ADVICE OR HELP? 

Chat with our friendly team today. 
Drop us a message, or give us a call on 0330 441 350.