Personal protective equipment is the last line of defence between a worker and a hazard. When all other control measures have been applied, PPE provides a critical barrier against injury and ill health. However, PPE can only protect workers if it is correctly selected, properly fitted, regularly inspected, and replaced when it reaches the end of its serviceable life.
This PPE inspection checklist covers the major categories of personal protective equipment and the key checks that should be performed to ensure each item remains fit for purpose and compliant with relevant standards.
Why PPE Inspections Matter
Damaged or degraded PPE can provide a false sense of security. A hard hat with a hairline crack may shatter on impact instead of absorbing the blow. A harness with frayed webbing may fail under load. Respiratory masks with worn seals allow hazardous substances to bypass the filter entirely. Regular inspections catch these defects before they lead to injury.
Employers have a legal duty under the Personal Protective Equipment at Work Regulations to ensure that PPE is maintained in an efficient state, in efficient working order, and in good repair. Documented inspections are the primary way to demonstrate compliance with these requirements. They also help organisations manage replacement cycles and budgets more effectively.
PPE Inspection Checklist
Head Protection
Hard hats and bump caps protect against falling objects, head strikes, and electrical contact. They must be inspected before each use and replaced after any significant impact.
- Shell is free from cracks, dents, gouges, and signs of UV degradation
- Suspension harness is intact and securely attached to the shell
- Headband and sweatband are clean and provide a comfortable, secure fit
- Hard hat is within the manufacturer's recommended replacement date
- Accessories such as chin straps and visors are correctly fitted and undamaged
Eye and Face Protection
Safety spectacles, goggles, and face shields protect against chemical splashes, flying particles, and harmful radiation. Damaged or scratched lenses reduce visibility and compromise protection.
- Lenses are free from scratches, cracks, and discolouration that impair vision
- Frames are not bent, cracked, or missing padding
- Side shields or wrap-around design provides adequate peripheral protection
- Anti-fog coatings are functioning and lenses can be cleaned effectively
Hearing Protection
Ear plugs and ear muffs reduce exposure to noise that could cause permanent hearing damage. The correct noise reduction rating must be matched to the hazard level.
- Ear muff cushions are soft, clean, and not cracked or hardened
- Headband tension holds the muffs firmly against the head without excessive pressure
- Disposable ear plugs are not reused beyond their intended lifespan
- Noise reduction rating is appropriate for the noise levels in the work area
Respiratory Protection
Respiratory protective equipment ranges from simple disposable masks to powered air-purifying respirators. Correct fit and filter selection are essential to ensure adequate protection.
- Face seal is intact and provides a tight fit with no gaps around the nose or chin
- Filters are within their expiry date and appropriate for the identified hazard
- Exhalation valves open and close freely and are not blocked or damaged
- Straps are elastic and hold the mask securely in position during movement
- Face-fit testing records are current for all workers using tight-fitting masks
Hand Protection
Gloves protect against cuts, abrasion, chemicals, heat, and cold. The correct glove type must be matched to the specific hazard, as no single glove provides universal protection.
- Gloves are free from tears, punctures, and excessive wear
- Chemical-resistant gloves show no signs of swelling, discolouration, or stiffness
- Cut-resistant gloves carry the correct EN 388 rating for the task
- Gloves fit properly and do not restrict dexterity to the point where they create new hazards
Fall Protection Equipment
Harnesses, lanyards, and self-retracting lifelines are life-critical equipment. Any defect could result in a fatal fall. Inspections must be thorough and carried out by a competent person.
- Webbing is free from cuts, fraying, burns, chemical damage, and UV degradation
- Buckles, D-rings, and connectors operate smoothly and lock securely
- Stitching is intact with no pulled, broken, or missing threads
- Labels are legible showing manufacturer, model, date of manufacture, and serial number
- Equipment has not been subjected to a fall arrest event since its last formal examination
Best Practices for PPE Inspections
- Train all workers to carry out pre-use visual inspections of their own PPE before every shift
- Schedule formal periodic inspections by a competent person at intervals specified by the manufacturer
- Remove any defective PPE from service immediately and label it clearly to prevent reuse
- Maintain an asset register that tracks each item of PPE by serial number, issue date, and inspection history
- Store PPE in clean, dry conditions away from direct sunlight, chemicals, and extreme temperatures
- Replace PPE in accordance with manufacturer guidance, even if it appears to be in good condition
How Checksheets Helps
Checksheets simplifies PPE management with digital inspection checklists tailored to each equipment type. Inspectors can record findings, photograph defects, and flag items for immediate replacement, all from a mobile device. Our platform tracks inspection histories and sends automated reminders when periodic inspections or replacement dates are approaching, ensuring that no item of PPE slips through the net.
With Checksheets, you can be confident that every piece of personal protective equipment in your organisation is accounted for, inspected, and ready to protect the people who depend on it.