When to Replace vs Repair Safety Gear

Every company tries to maximize the lifespan of its equipment — but with safety gear, pushing it too far can cost more than just money. Knowing when to repair and when to replace is key to protecting your team and staying compliant.

Here’s a practical guide for procurement managers, HSE officers, and business owners to make smart, safety-first decisions.

1. Replace Any PPE That’s Compromised in Structure or Function

If the item’s protective function is no longer guaranteed, it must be replaced — no exceptions.

Examples that require replacement:

• A hard hat with cracks or visible deformation

• Safety goggles with scratched or fogged lenses

• Cut gloves with visible tears or frayed seams

• Respirators with damaged seals or expired filters

• Hi-vis vests with faded fabric or reflective tape

If in doubt — swap it out.

2. Repair Only When Certified and Approved

Some gear can be safely repaired — but only under strict guidelines and with manufacturer-approved methods.

Examples where repair may be acceptable:

• Replacing hard hat suspensions (using OEM parts)

• Re-threading uniform seams (not in critical impact areas)

• Replacing buckles or clips on harnesses — if certified by the supplier

• Installing new filter cartridges in reusable respirators

Always document repairs, and never DIY fix critical safety items unless trained and authorized.

3. Watch for Expiry Dates

PPE isn’t forever. Even if it looks fine, materials degrade with time and environmental exposure.

Examples with expiry risks:

• Hard hats (3–5 years from manufacturing date)

• Respirators and cartridges

• Flame-resistant uniforms after excessive washing

• Safety shoes with compressed midsoles or worn tread

Use PPE logs or digital systems to track purchase dates and expiry timelines across departments.

4. Consider the Cost of Downtime and Liability

If damaged PPE leads to an accident, your company could face:

• Legal and insurance claims

• Penalties for non-compliance

• Project delays

• Loss of reputation

In many cases, replacing gear is cheaper than dealing with the aftermath of unsafe equipment.

5. Standardize a Replacement Policy

Create a company-wide guideline that clearly defines:

• Replacement timelines by PPE type

• Repair conditions and who approves them

• Roles responsible for inspection and reporting

Train supervisors to enforce it on-site. Make safety non-negotiable.

Final Thought

Repairing gear makes sense — until it becomes a risk. Knowing when to retire equipment is a key part of risk management. TFQ Trading supplies safety gear with full documentation and supports clients with replacement schedules and compliant spare parts.