Toolbox Talks · Mandatory · Construction

Toolbox Talk — PPE Use and Maintenance

A toolbox talk on the correct selection, use, storage, and maintenance of personal protective equipment.

Last reviewed: 29 March 2026 — This guide reflects UK law as of this date. PPE Regs 2022 remains current with no amendments enacted as of 29 March 2026. Next scheduled review: 29 March 2027.

1. The Last Line of Defence

Personal Protective Equipment is the last resort in the hierarchy of control — not the first response. The Personal Protective Equipment at Work Regulations 2022 (replacing the 1992 Regulations) and the Management of Health and Safety at Work Regulations 1999 (MHSWR) require employers to eliminate or reduce risk through engineering controls, safe systems of work, and organisational measures before relying on PPE. When residual risk remains after all other controls have been applied, PPE provides the final barrier between the hazard and the worker.

The PPE at Work Regulations 2022 brought a significant change: the duty to provide PPE free of charge was extended to limb (b) workers — those who are not employees but work under the direction of the employer — and to self-employed persons. This closed a longstanding gap in protection. On construction sites, this means agency workers, labour-only subcontractors, and self-employed operatives must all receive PPE from the duty holder at no cost. PPE must also be maintained, replaced when damaged or worn, and workers must be trained in its correct use.

Hard hats have a finite service life — replace after any impact and after five years maximum

Thermoplastic hard hats (the most common type on construction sites) degrade with UV exposure, temperature extremes, and age. Manufacturers typically recommend replacement after five years from manufacture regardless of visible condition. After any impact — even if no visible damage is present — the hard hat must be replaced. The internal harness should be inspected at every pre-use check and replaced if frayed, cracked, or deformed.

2. Key Talk Points

Talk Point	Detail
Site mandatory PPE	EN 397 hard hat (or EN 12492 where chin strap is required), EN ISO 20471 hi-vis vest or jacket (Class 2 minimum), and EN ISO 20345 safety boots with steel or composite toe cap. These three items are mandatory at all times on site for all personnel. No exceptions.
Task-specific PPE	Eye protection (EN 166) for cutting, grinding, drilling, and demolition. Hearing protection (EN 352) in noise zones above 85 dB(A). Respiratory protective equipment (RPE) for dust, fumes, and vapours — type determined by COSHH assessment. Gloves matched to the hazard: chemical-resistant for substances, cut-resistant for sharp materials, thermal for hot works.
Pre-use check	Every item of PPE must be visually inspected before each use. Hard hats: check shell for cracks, dents, UV degradation (chalky surface); check harness for fraying and adjustment. Boots: check sole integrity, toe cap exposure, lace condition. Hi-vis: check reflective strips for delamination and garment for tears. RPE: check seal, valves, filters, and expiry.
Replacement	PPE that is damaged, worn, or beyond its service life must be replaced immediately. Workers must not be expected to continue working with defective PPE. Replacement PPE must be provided free of charge. A clear process for requesting and obtaining replacement PPE must be communicated at induction.
Face-fit testing	Any tight-fitting RPE (FFP2, FFP3, half-mask, full-face mask) requires face-fit testing before first use. Testing must be repeated if the wearer's face shape changes (significant weight change, dental work, scarring). Records of face-fit tests must be kept and available on site. Workers who cannot achieve a seal must be provided with alternative RPE (powered air or hood type).

3. Common Mistakes

Hard hats kept beyond their service life

Thermoplastic hard hats degrade over time even without visible damage. Check the manufacture date moulded inside the shell. If the hat is more than five years old, replace it regardless of appearance. Many sites fail to check dates during inspections. A systematic check at induction and during weekly inspections prevents aged hard hats remaining in use.

Worn boot soles not identified or replaced

Safety boots with smooth, worn soles provide inadequate grip on wet, muddy, or oily surfaces. The tread pattern is the primary slip-resistance feature of the boot. Once tread depth is significantly reduced, the boot must be replaced. Boot condition should be checked at induction and during site inspections. Workers must be able to obtain replacements without cost or delay.

Removing PPE in unsupervised areas

Workers removing hard hats, hi-vis, or hearing protection when they believe they are not being observed is a persistent problem. The hazard does not disappear because a supervisor is not present. PPE requirements are based on risk assessment, not supervision. The culture must reinforce that PPE protects the wearer — it is not worn for the benefit of management.

Using FFP1 or FFP2 masks for silica dust

Respirable crystalline silica (RCS) requires FFP3 protection as a minimum. FFP1 provides inadequate filtration. FFP2 does not meet the assigned protection factor required for silica exposure. The COSHH assessment determines the RPE type — for silica, the answer is always FFP3 or higher. Workers supplied with FFP1 or FFP2 for silica-generating tasks are being exposed to a workplace exposure limit exceedance.

Subcontractor workers not receiving PPE

The PPE at Work Regulations 2022 extended the duty to provide PPE to limb (b) workers and the self-employed. Subcontractor operatives, agency workers, and self-employed persons must receive PPE from the duty holder free of charge. It is not acceptable to expect subcontractor workers to provide their own PPE unless the subcontract specifically addresses this and the PPE meets the required standards.

4. Frequently Asked Questions

What do the EN standards on PPE actually mean?▾

EN standards are harmonised European standards that define performance requirements for PPE. EN 397 covers industrial safety helmets — specifying impact absorption, penetration resistance, and flame resistance. EN ISO 20345 covers safety footwear — the S-rating defines the level of protection (see S1/S1P/S3 below). EN ISO 20471 covers high-visibility clothing — Class 1 is the lowest visibility, Class 3 the highest. EN 166 covers eye protection. EN 352 covers hearing protectors. The EN marking on PPE confirms it has been tested and certified to the relevant standard. PPE without valid EN certification should not be used on UK construction sites.

Can workers use their own PPE instead of site-issued PPE?▾

Workers may use their own PPE provided it meets the same EN standards required by the site, is in good condition, and has been approved by the site manager. The duty holder retains responsibility for ensuring all PPE on site is adequate regardless of who purchased it. If a worker's own PPE does not meet the standard, the duty holder must provide compliant PPE free of charge. In practice, most principal contractors issue standard PPE to ensure consistency and compliance.

How long is a face-fit test valid?▾

There is no fixed expiry period defined in law. HSE guidance (INDG 479) states that face-fit testing should be repeated whenever there is a change that could affect the seal: significant weight gain or loss, dental work, facial scarring, or a change in the make or model of RPE. In practice, many organisations retest annually as good practice. The test is specific to the make and model of RPE — a worker face-fit tested on one mask is not automatically cleared for a different mask. Records must be kept and available on site.

What is the difference between S1, S1P, and S3 safety boots?▾

S1 boots have a protective toe cap (200 joules), closed seat region, antistatic properties, and energy-absorbing heel. S1P adds a penetration-resistant midsole (protecting against nails and sharp objects underfoot). S3 includes everything in S1P plus a water-resistant upper and cleated outsole for improved grip in outdoor and rough terrain conditions. On most construction sites, S3 is the minimum standard required because of the combination of outdoor conditions, rough terrain, and the risk of nail or sharp object penetration. S1 and S1P may be acceptable for indoor fit-out work where conditions are controlled.

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