Work Activities · 6 checks · 1 critical

PPE Compliance
safety audit checklist

Hard hats, hi-vis, boots, task-specific PPE.

Every check below says what good looks like, when it passes, the regulation or HSE guidance it rests on and the defects that usually fail it. Critical checks are marked: a fail on one of those stops the activity.

  1. 1.
    All personnel wearing hard hats in designated zones
    Critical: a fail stops the work
    What to look forHard hats marked to BS EN 397 (industrial) or BS EN 12492 (high-work/with chinstrap). Worn correctly, peak forward, not backwards (unless model designed for it), harness adjusted, chinstrap if working at height. Within shelf life (5yrs from manufacture date moulded into hat, 2-3yrs from first use typical).
    Acceptable whenPPE at Work Regs 1992 (as amended 2022). Hard hats mandatory across construction sites except in offices/canteens (HSE Construction (Head Protection) Regs 1989, revoked but principle continues under PPE Regs). EN 397 minimum spec; chinstraps where working at height.
    StandardPPE at Work Regs 1992 (amended 2022). BS EN 397:2012+A1:2012. BS EN 12492:2012. HSWA 1974 s.7. INDG174, A short guide to the PPE Regs.
    Common defectsWorn out of date, manufacture date 6+ years agoCracked shell from previous impact, still in useStickers/paint applied, degrades shellNo chinstrap when working at heightHat too loose, falls off in stoop workVisitors without PPE, Principal Contractor liability
  2. 2.
    All personnel wearing high-vis
    What to look forClass 2 (vest/waistcoat with bands) minimum on most sites; Class 3 (long sleeves + bands) where vehicles operate or in low light. Clean, not grease-stained or faded, fluorescence works only when bright. Sized correctly, fastened. Banksmen often wear distinct colour (red/orange) to differentiate.
    Acceptable whenPPE at Work Regs 1992. BS EN ISO 20471:2013+A1:2016, high-visibility clothing. Class 2 vest minimum on construction; Class 3 in vehicle/highway environments. Replaced when fluorescence faded.
    StandardPPE at Work Regs 1992. BS EN ISO 20471:2013+A1:2016. Chapter 8 (highways) for highway works.
    Common defectsFaded / grey from washing, no longer fluorescentClass 1 vest in vehicle environment (insufficient)Bands worn / peeled awayHi-vis under non-hi-vis jacket, defeats purposeBanksman in same colour as workforce, not distinguishable
  3. 3.
    Safety boots worn by all operatives
    What to look forBoots marked S3 or S5, toe cap (200J), midsole penetration resistance, water resistant upper, oil resistant sole. Ankle support (rigger or full lace boot), not low cut shoes. Sole tread not worn smooth. Visitors issued or refused entry. No trainers or canvas footwear.
    Acceptable whenPPE at Work Regs 1992. BS EN ISO 20345:2022, safety footwear. Minimum S3 for general construction (toe + midsole + waterproof upper). S5 wellington for groundworks. Replaced when sole worn or upper breached.
    StandardPPE at Work Regs 1992. BS EN ISO 20345:2022. INDG174.
    Common defectsTrainers worn under hi-vis trousersSole tread worn smooth, slip riskToe cap exposed through worn upperRigger boot in groundworks, sand/grit getting inWet rotted leather no longer waterproof
  4. 4.
    Task-specific PPE being used (gloves, eye, hearing)
    What to look forGloves matched to hazard, cut resistant (EN 388 cut Level C/D/E for sharp materials), chemical (EN 374 with breakthrough time), heat (EN 407). Safety glasses (EN 166 1F) for grinding, drilling, cutting; goggles where dust/splash; face shield for high impact. Ear defenders/plugs for noise.
    Acceptable whenPPE at Work Regs 1992, risk assessment must drive PPE selection. EN 388 (gloves), EN 166 (eye), EN 352 (hearing). Each hazard has its specific PPE, no "general purpose" cover-all.
    StandardPPE at Work Regs 1992. BS EN 388:2016+A1:2018 (gloves). BS EN 166:2002 (eye). BS EN 352-1/2/3 (hearing).
    Common defectsGeneric rigger gloves used for cutting metal, sliced throughNo eye protection during grinding, debris injuriesWrong glove for chemicals, solvent breakthroughEar plugs not rolled/inserted correctly, minimal attenuationNo face fit testing for tight-fit RPE
  5. 5.
    RPE used where dust/fume exposure
    What to look forRPE selected from substance exposure assessment, disposable FFP3 mask for general construction dust; half-mask or full-face for higher exposure or specific contaminant; powered air for chemicals/abrasive blasting. Face fit test on file (every 2 years, sooner if facial change). Not worn over beard.
    Acceptable whenCOSHH 2002. HSG53, Respiratory protective equipment at work. Tight-fitting RPE requires face fit test (Fit2Fit or equivalent). Operatives clean shaven where tight-fit. Stored clean and dry.
    StandardCOSHH 2002. HSG53. INDG479, Guidance on RPE fit testing. Approved Code of Practice L5.
    Common defectsFFP3 worn over a beard, no sealNo face fit test on fileWrong protection level (FFP1 used for silica)RPE not stored clean, contaminated next useNo filter change records on reusable masks
  6. 6.
    PPE in good condition, no damaged items in use
    What to look forNo cracked hats, holed gloves, scratched/pitted lenses, frayed harness webbing, expired RPE filters. PPE inspection on issue and pre-use. Damaged PPE replaced not bodged. Storage in clean, dry, lit area. Daily/weekly checks documented for harnesses (LOLER 6-monthly thorough exam).
    Acceptable whenPPE at Work Regs 1992 Reg 7, PPE maintained in efficient state, working order and good repair. Reg 9, replaced when no longer effective. LOLER 1998 for harness/lanyards: 6-monthly thorough examination.
    StandardPPE at Work Regs 1992. LOLER 1998 (lifting accessories). Manufacturer cleaning and storage instructions. INDG174.
    Common defectsHelmet shell cracked but still in useHarness webbing chemical-burned and not retiredGlasses pitted, visibility reducedGlove finger holed, exposing skin to hazardNo documented inspection regime for harnesses

Questions people ask

How often should a ppe compliance audit be done?

Weekly is the common rhythm for a live site, plus whenever the work, the plant or the people change and after any incident or near miss. What matters is that it is scored, recorded, dated and the actions are closed out, not the exact frequency. Guidance, not legal advice.

What is the difference between a safety audit and an inspection?

An inspection looks at the site. An audit checks the system as well: is the paperwork there, do the people know it, is what was promised actually happening. On a small site the words blur, and that is fine. The checks below cover both.

What happens with a failed item?

A corrective action with an owner and a date, and a photo of the fail so nobody argues later. 1 of the 6 checks here are marked critical: a fail on one of those stops that activity until it is put right.

Who should carry out the audit?

A competent person, and where possible not the person whose work is being looked at. The site manager auditing the site manager's housekeeping is better than nothing, but a visiting supervisor or the SHEQ lead sees what the regular eye has stopped noticing.

Is a site safety audit a legal requirement?

The Management of Health and Safety at Work Regulations 1999 require arrangements for monitoring your health and safety measures (regulation 5), and CDM 2015 requires every contractor to plan, manage and monitor the work under their control (regulation 15). A recorded, scored audit is how you show that is happening. Guidance, not legal advice.

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