Personal protective equipment (PPE) is often the last line of defense between workers and workplace hazards. OSHA requires employers to provide, maintain, and ensure the proper use of PPE wherever hazards cannot be eliminated through engineering or administrative controls. Under 29 CFR 1910.132, defective or damaged PPE shall not be used — making regular inspection a fundamental requirement. This guide covers the complete inspection requirements for all major PPE categories and provides a free downloadable checklist to standardize your inspections.
Free PPE Inspection Checklist
Download our Word document checklist covering all major PPE categories: eye, face, head, hand, foot, and body protection.
Download Checklist (.docx)Why PPE Inspections Are Required
OSHA 29 CFR 1910.132 — General Requirements
- 1910.132(a): PPE shall be provided, used, and maintained in a sanitary and reliable condition wherever hazards are present.
- 1910.132(d): Employers must conduct a hazard assessment, select appropriate PPE, ensure proper fit, and certify the assessment in writing.
- 1910.132(e): Defective or damaged personal protective equipment shall not be used.
- 1910.132(f): Employees must be trained on when PPE is necessary, what PPE is required, how to properly don and doff, PPE limitations, and proper care, maintenance, useful life, and disposal.
Equipment-Specific Standards
- 1910.133: Eye and face protection — must meet ANSI Z87.1 performance requirements.
- 1910.135: Head protection — must meet ANSI Z89.1 for industrial head protection.
- 1910.136: Foot protection — must meet ANSI Z41 or ASTM F2413 for protective footwear.
- 1910.138: Hand protection — selection based on hazard assessment for the specific tasks performed.
- 1910.134: Respiratory protection — separate standard with its own inspection, fit testing, and medical evaluation requirements.
Important: PPE is not a substitute for engineering controls, work practice controls, or administrative controls. The hierarchy of controls requires eliminating or reducing hazards before relying on PPE. When PPE is necessary, it must be properly selected, fitted, maintained, and inspected.
Eye and Face Protection
| Inspection Item | What to Check |
|---|---|
| Lenses | No cracks, chips, scratches, or pitting that impair vision. Lenses seat securely in frame. Anti-fog coating functional (if applicable). Correct shade/tint for the hazard. |
| Frame and temples | No cracks, bending, or distortion. Temples maintain proper tension and fit. Hinges function smoothly. Side shields present and attached (if required). |
| Straps and headband | Goggles: headband elastic and adjustable, no fraying. Face shields: headgear ratchet functions, suspension provides secure fit. No deterioration of materials. |
| Ventilation | Goggle vents not blocked. Indirect vents intact for splash protection. Anti-fog features functional. |
| Markings | ANSI Z87.1 marking visible on lens and frame. Impact rating (Z87+) present if required. Manufacturer identification legible. |
Head Protection
| Inspection Item | What to Check |
|---|---|
| Shell | No cracks, dents, gouges, or penetration holes. No chalking, fading, or brittleness from UV exposure. No unauthorized holes, paint, stickers, or modifications that could compromise integrity. |
| Suspension system | All attachment points connected and secure. Headband adjustable and maintains fit. Crown straps intact with no tears, cuts, or excessive stretching. Provides proper standoff distance between shell and head. |
| Brim and peak | No cracks or chips along the brim. Full-brim or cap style appropriate for the hazard. No warping or deformation. |
| Electrical rating | Class E (electrical, 20kV) or Class G (general, 2.2kV) appropriate for electrical exposure. No conductive materials added (metal stickers, accessories). |
| Markings and age | ANSI Z89.1 compliance marking visible. Type (I or II) and class (E, G, or C) legible. Check manufacturer date — replace per manufacturer guidelines (typically 2–5 years from first use). |
Hand Protection
| Inspection Item | What to Check |
|---|---|
| Physical condition | No holes, tears, punctures, or thinning. No excessive wear at fingertips or palm. Seams intact with no separation. |
| Chemical resistance | Chemical-resistant gloves: no swelling, stiffening, softening, or discoloration from chemical exposure. Check against manufacturer's chemical compatibility chart and breakthrough time data. |
| Cut resistance | Cut-resistant gloves: ANSI/ISEA 105 cut level appropriate for task. No cuts or nicks in the protective material. Coating (if applicable) intact with no peeling. |
| Flexibility and fit | Gloves maintain flexibility for the required dexterity. Proper size — not too tight (reduces circulation) or too loose (catch hazard). Cuff length adequate for the exposure. |
| Insulation (if applicable) | Thermal or electrical insulating gloves: no damage to insulating layer. Electrical gloves tested per OSHA 1910.137 and ASTM D120 at required intervals. Leather protectors over electrical gloves in serviceable condition. |
Foot Protection
| Inspection Item | What to Check |
|---|---|
| Safety toe | Steel, composite, or alloy toe cap not exposed, dented, or cracked. Toe area of upper leather/material intact over the cap. |
| Soles | Adequate tread depth for slip resistance. No separation from upper. Puncture-resistant plate intact (if applicable). No chemical degradation or excessive wear. |
| Upper and closures | No holes, tears, or excessive wear in the upper material. Laces, buckles, or zippers functional. Metatarsal guard intact (if applicable). |
| Electrical hazard rating | EH-rated boots: sole and heel intact with no cracks, holes, or wear-through that would compromise electrical insulation. No conductive modifications. |
| Markings | ASTM F2413 compliance marking visible. Protection ratings (impact I/75 or I/50, compression C/75 or C/50) appropriate for hazards. EH, MT, PR markings present as required. |
High-Visibility and Body Protection
| Inspection Item | What to Check |
|---|---|
| High-visibility garments | ANSI/ISEA 107 class appropriate for the work environment. Retroreflective strips clean, intact, not peeling or cracked. Background fluorescent material not faded. Garment clean enough to maintain visibility. |
| Protective clothing | Chemical-resistant suits/aprons: no holes, tears, or chemical degradation. Seams sealed. Closures (zippers, snaps) functional. FR clothing: no holes, tears, or contamination with flammable substances. |
| Hearing protection | Earplugs: no hardening, cracking, or shrinkage. Earmuffs: cushions pliable, no cracks or leaks; headband maintains pressure; no modifications. NRR rating adequate for noise exposure. |
Hazard assessment documentation: OSHA 1910.132(d)(2) requires a written certification of the hazard assessment that identifies the workplace evaluated, the certifying person, the assessment date, and identifies the document as a certification of hazard assessment. This certification must be on file and available for inspection. Review and update the assessment whenever processes, equipment, or hazards change.
Corrective Actions
When to Replace PPE
- Any damage that reduces the protective capability below the required level
- Chemical exposure that degrades materials beyond manufacturer specifications
- Impact or stress that exceeds the design limits (hard hats after a significant blow)
- Expiration of useful service life as specified by the manufacturer
- UV degradation of hard hat shells (chalking, fading, brittleness)
- Missing or illegible compliance markings or labels
- Failed fit testing (respirators) or loss of proper fit
- Contamination that cannot be properly decontaminated or cleaned
Best Practices
PPE Program Management
Maintain a PPE inventory by department and job task linked to the hazard assessment. Track issuance, inspection, and replacement by employee. Use inspection software to schedule and document routine PPE audits. Integrate PPE compliance checks into regular workplace safety inspections. Training management software ensures all employees are current on PPE training and can demonstrate proper use.
Download the Free Checklist
Get our PPE inspection checklist in Word format. Customize it for your specific hazard assessment and required PPE types.
Download Checklist (.docx)
Go digital with Ecesis. Replace paper PPE inspection logs with Ecesis inspection software. Track PPE by employee and department. Link inspections to your hazard assessment. Schedule routine PPE audits with automated reminders. Capture photos of defective equipment. Generate audit-ready reports. Request a free demo.
Ecesis EHS Software
Inspections
Digital inspection forms with mobile completion, photo capture, and corrective actions.
Safety Inspections
Workplace safety inspections with PPE compliance verification built in.
Training
Track PPE training, hazard assessment certifications, and retraining requirements.
Preventive Maintenance
Schedule PPE replacement cycles, electrical glove testing, and equipment recertifications.
Compliance Calendar
Track hazard assessment review dates, training renewals, and inspection schedules.
Task Management
Assign corrective actions for defective PPE, track replacement orders to completion.
