Introduction

Personal Protective Equipment (PPE) is a vital line of defence in safeguarding workers' health and safety. But providing the right kit is only the first step.

Maintaining it correctly and ensuring compliance are equally critical. Skimp on maintenance or fail to enforce proper use, and the risks to staff and business alike quickly mount.

1. Legal Responsibilities & Regulatory Framework

Since 1st January 1993, the Personal Protective Equipment at Work Regulations 1992 (recently updated by the PPE at Work Regulations 2022) have placed a statutory duty on employers to:

• Provide suitable PPE to anyone exposed to health or safety risks at work
• Ensure it is maintained, stored correctly, and replaced as needed
• Supply appropriate training and make PPE use mandatory where required
• Provide PPE free of charge, even for "limb (b)" workers such as contractors or gig workers

Non-compliance opens businesses to enforcement action, fines, or even prosecution - especially if an incident arises from faulty or improperly maintained equipment.

2. How Maintenance Safeguards Effectiveness

According to Health and Safety Executive (HSE) guidance, proper PPE care means:

• Cleaning and storing equipment in a clean, dry cupboard when not in use
• Following manufacturer replacement schedules (e.g. replacing worn straps or filters before they fail)
• Regularly checking for damage: tears in gloves, degraded hi-vis striping, cracked helmets, corroded respirators
• Knowing who is responsible for maintenance and ensuring replacements are available promptly

Maintenance isn't optional - it's central to effectiveness. For example, dirty hi-vis jackets quickly lose reflectivity, making them far less protective.

3. The Human Cost of Poor PPE Compliance

HSE's latest figures for Great Britain (2023/24) report:

• 561,000 non-fatal workplace injuries
• 135 fatal injuries
• Over 1.8 million cases of work-related ill health, spanning musculoskeletal disorders, stress, respiratory conditions and more

A separate survey within UK healthcare found adherence to PPE use at just 80%, with hand hygiene at only 67.8%. This inconsistency leaves workers unnecessarily exposed.

4. Financial & Operational Impact of Non-Compliance

Failing to maintain or enforce PPE routines carries heavy costs:

• Higher compensation and settlement claims, including legal fees
• Rising insurance premiums, due to poor safety records
• Lost productivity when injured staff are absent, plus the expense of temporary cover or retraining
• Enforcement penalties under HSE regulations can reach significant sums

Avoiding these issues makes PPE maintenance both a safety and a sound business decision.

5. Best Practice: Practical Steps for Employers

To ensure PPE is always up to scratch:

• Maintain a PPE register – track issue dates, inspections, replacements, and responsible persons
• Train employees not just in correct use, but how to inspect, clean, and report defects
• Carry out routine inspections – daily visual checks by users plus periodic formal reviews
• Replace items proactively, not reactively. Timely replacement avoids failure during use
• Store gear correctly – temperature controlled, clean storage away from contamination or moisture
• Review PPE policies regularly, particularly when tasks or equipment change

6. Why Maintenance Matters: Bottom Line Benefits

• Keeps PPE effective, ensuring hazards remain controlled.
• Reduces incidents, injury rates, and ill health - protecting your workforce.
• Strengthens compliance, meeting your legal duties under PPE Regulations.
• Controls costs, by averting claims, fines and downtime.

Conclusion

PPE is only protective when it's in good working order and used consistently. Regular maintenance, combined with a robust compliance regime, is your guarantee that PPE delivers as intended - ensuring staff safety and protecting your business.

At Dalton Safety, we help businesses put these systems in place, ensuring your PPE programme isn't just nominal but genuinely effective.

Written by Harry Dalton, Dalton Safety