Free Tool · PPE Inspection Checklist
PPE Inspection & Replacement Tracker
Use this checklist to inspect PPE by category before issue and at regular intervals. Check off each item as it passes inspection, and treat any failed item as a trigger to withdraw the equipment from use immediately.
Head Protection
- Shell free of cracks, dents or deep scratches.
- Harness and straps intact with no fraying.
- No signs of chemical damage, discoloration or chalking.
- Within manufacturer’s stated service life from date of manufacture.
- Not exposed to a significant impact since last inspection (retire after any real impact).
Eye and Face Protection
- Lens free of scratches that impair vision.
- Frame and side shields intact with no cracks.
- Anti-fog or anti-scratch coating not significantly degraded.
- Straps or arms hold the protector securely in place.
Hearing Protection
- Earmuff cushions free of cracks and fully sealing.
- Headband tension still holds cups firmly against the head.
- Foam earplugs are clean, not misshapen or reused beyond intended use.
- No visible hardening or shrinking of ear plug material.
Respiratory Protection
- Mask body free of cracks, tears or distortion.
- Straps have full elasticity and secure the mask firmly.
- Filters within their service life and not visibly damaged or wet.
- Valves move freely and seat correctly.
- A fit test has been completed for this specific mask and wearer.
Hand Protection
- No holes, tears or thinning at fingertips and palm.
- Chemical-rated gloves show no discoloration, swelling or stiffening.
- Cut-resistant gloves show no significant fraying of the liner.
- Within the documented breakthrough time if used for chemical contact.
Foot Protection
- Sole tread not excessively worn, especially at heel and ball.
- No visible separation between sole and upper.
- Toe cap and midsole protection show no cracks or exposure.
- Waterproofing or chemical resistance not visibly compromised.
Fall Protection Equipment
- Webbing free of cuts, fraying, burns or chemical staining.
- Stitching intact with no pulled or broken threads.
- Metal connectors free of cracks, corrosion or deformation.
- Energy absorber indicator not triggered.
- Within manufacturer’s stated service life and inspection interval, with inspection tag current.
How to Use This Tool
Work through the category relevant to the equipment in front of you before each use, and repeat a full inspection at the interval set by your organization or the manufacturer. Any single failed item means the equipment should be taken out of service, not just noted for later.
Why Visual Inspection Is Not Always Enough
Some damage, such as internal harness stitching or filter saturation, cannot always be seen from the outside. Follow the manufacturer’s full inspection procedure for fall protection and respiratory equipment in particular, and observe fixed replacement intervals even when equipment still looks acceptable.
Relevant standards:
Frequently Asked Questions
How often should PPE be formally inspected?
Frequency depends on the equipment type and manufacturer instructions – fall protection typically needs at least an annual formal inspection by a competent person, in addition to pre-use checks by the wearer every time.
Who can carry out a formal PPE inspection?
Pre-use checks can be done by the wearer, but periodic formal inspections, especially for fall protection equipment, should be carried out by someone trained and competent to recognize equipment-specific defects.
Should PPE be replaced even if it looks fine?
Yes, once it reaches the manufacturer’s stated service life or has been involved in an event such as a fall arrest, it should be retired regardless of visual condition.
What records should be kept for PPE inspection?
Date of inspection, inspector name, equipment identification, condition found, and any action taken should be recorded, particularly for fall protection and respiratory equipment subject to formal inspection regimes.
Can damaged PPE ever be repaired instead of replaced?
Only if the manufacturer explicitly permits repair for that specific defect and equipment type. Unauthorized repairs, especially to fall protection or respiratory equipment, can compromise the certified protection level.
Explore the full EN Standards Library for every standard referenced above, or read real Field Stories showing what happens when procedures are skipped.