Is your team's safety gear still effective? Worn-out high-visibility clothing puts workers at risk. It feels like a small issue until an accident happens because someone wasn't seen.

You should replace high-visibility clothing when it is faded, torn, soiled, or when the reflective tape is cracked or lost its brightness. A key test is if the garment is no longer visible from 1,000 feet (about 305 meters) at night.

It’s easy to overlook a faded vest or a dirty jacket. We see them every day, and they seem "good enough." But "good enough" is a dangerous gamble when lives are on the line. The gradual decline in a garment's visibility is hard to notice day-to-day. This slow fade is a silent risk. Over my years in this industry, I've learned that proactive replacement isn't just a best practice; it's a critical safety measure. Understanding the exact signs of wear and the standards that govern them is the best way to protect your team. We need to move from guessing to knowing.

When should high-visibility clothing be replaced?

Worried your hi-vis gear is past its prime? Faded colors and worn-out tape mean workers blend into the background. This puts them in serious danger of not being seen by drivers.

Replace high-visibility clothing¹//arxiv.org/html/2503.14801v1)² clothing immediately when you see clear signs of wear. This includes faded³ fluorescent fabric, cracked or peeling reflective stripes, and permanent dirt or stains. These flaws seriously reduce the garment's ability to keep workers visible and safe from accidents.

The visual cues for replacement are quite clear once you know what to look for. It's not about a fixed date on a calendar but about the physical condition of the garment. Daily wear and tear⁴, exposure to sunlight, and improper washing all contribute to degradation. A simple but effective method is the comparison test. Take a worn garment and hold it next to a brand-new one. The difference in color vibrancy and reflectivity⁵ will often be shocking. As a manufacturer, we stress that the materials are designed to be eye-catching, but they have a finite lifespan. Once that brightness is gone, the protection is gone too. Regular inspection should be part of every safety program⁶.

Here are the key warning signs:

How often should workwear be replaced?

Does your company have a clear replacement schedule⁷ for workwear? Without one, employees might wear unsafe gear for too long. This creates a huge liability if an accident occurs.

There is no single rule for how often to replace workwear. It depends entirely on the work environment, how often it's worn, and how it's cared for. A construction worker might need new gear every 6 months, while an event marshall might use theirs for over a year.

The lifespan of a high-visibility garment is determined by its use. Think about the difference between a road crew worker exposed to sun, dirt, and rain every day versus a warehouse manager who only wears a vest during site visits. The road worker's vest will degrade much faster. Sunlight (UV radiation) is a primary cause of fading in fluorescent materials. Dirt and grime can mask the bright colors and diminish the reflective tape⁸'s power. Even washing the garment incorrectly, like using harsh detergents or high heat, can damage the materials and shorten its life. That’s why at Vissafety, we provide clear washing instructions with every piece. A good rule is to inspect gear regularly and replace it based on condition, not just time.

Here’s a general guide based on work environment:

When should high-visibility clothing be worn?

Are your workers wearing hi-vis gear⁹ only when it feels necessary? This inconsistent approach is risky. An accident can happen in seconds in conditions where visibility is poor.

High-visibility clothing must be worn whenever a worker is exposed to risks from moving vehicles or equipment. This includes low-light conditions¹⁰ (dawn, dusk, night), bad weather (rain, fog, snow), and any area where vehicles and people mix, like construction sites¹¹ and roadways.

The core principle is simple: see and be seen. High-visibility clothing is personal protective equipment (PPE) designed for one specific job—making the wearer stand out from their background. This is most critical when the background is visually "busy" or during low-light hours when the human eye struggles to detect shapes and colors. For example, a worker near a busy highway needs to be conspicuous to drivers traveling at high speeds. Similarly, a crane operator needs to clearly see the ground crew below them. It's not just about roadways. Warehouses with forklift traffic, airports with ground vehicles, and any site with heavy machinery present the same risks. As a manufacturer, we produce garments for different risk levels, ensuring there is a compliant solution for every scenario.

What are the OSHA requirements¹² for high-visibility clothing?

Feeling uncertain about OSHA's rules on hi-vis clothing? This confusion can lead to non-compliance and put your workers at risk. Fines for violations can be steep and damaging.

OSHA requires high-visibility clothing for workers exposed to vehicle hazards, as stated in standards like 29 CFR 1926.651. It recognizes the ANSI/ISEA 107 standard as the benchmark for compliance, mandating gear that is appropriate for the work environment and risk level.

OSHA's rules are built around protecting workers from recognized hazards. For anyone working near moving vehicles, being struck is a major hazard. While OSHA doesn't have a single, all-encompassing rule that says "you must wear this vest," it does have specific requirements in its construction and general industry standards. The key is the "General Duty Clause," which requires employers to provide a workplace free from recognized hazards. OSHA points to the ANSI/ISEA 107 standard as the accepted industry consensus on how to address visibility hazards¹³. Complying with ANSI 107 is considered the best way to comply with OSHA's expectations. We design all our Vissafety products to meet or exceed these standards, so our clients know they are providing compliant and effective protection.

What is the British standard¹⁴ for high visibility clothing?

Are you selling or working in the UK or EU and confused by the standards? Using non-compliant gear is a serious safety and legal misstep. It could invalidate insurance and lead to fines.

The British and European standard for high-visibility clothing is EN ISO 20471. This standard specifies the requirements for color, reflectivity⁵, and the minimum areas of visible materials to classify garments into one of three classes. Class 3 provides the highest level of visibility.

EN ISO 20471 is the globally recognized benchmark for hi-vis clothing, and it's the law for gear used in the UK and across Europe. It's a performance-based standard, meaning it’s not just about making a garment bright; it’s about proving its effectiveness. The standard is broken down into three main components: the fluorescent material (the background), the retro-reflective material (the tape), and the placement of those materials on the garment. Garments are tested for color fastness and reflective performance even after multiple washes. As a certified manufacturer, we have an in-house lab with over 75 devices to test our products against every requirement of EN ISO 20471. This ensures our clients receive gear that is fully compliant and reliable.

What is the ANSI standard for high-visibility clothing?

Struggling to navigate the ANSI/ISEA 107 standard? Choosing the wrong Type or Class can leave your team unprotected and your company non-compliant, especially in the North American market.

The American standard is ANSI/ISEA 107. It defines garment Types based on the work environment (O, R, or P) and Performance Classes (1, 2, or 3) based on the amount of visible material. For roadway workers, Type R, Class 2 or 3 is typically required.

The ANSI/ISEA 107 standard is the definitive guide for high-visibility safety apparel¹⁵ in the United States. A key update in recent years was the introduction of "Types." This helps users select the right gear for their specific environment. Type O is for off-road workers (like warehouse staff), Type R is for roadway workers, and Type P is for public safety (like police and firefighters). Within each Type, there are Performance Classes. Class 1 offers minimal visibility and is not suitable for roadway use. Class 2 is the most common requirement for workers near traffic. Class 3 offers the highest level of visibility for workers in complex, high-risk environments. We work closely with clients like Danny Cheng from California to ensure the products we develop meet the exact ANSI/ISEA 107 requirements for his market.

What is the ISO standard for high visibility clothing?

Are you sourcing hi-vis gear for a global team? Managing different regional standards can be a complex headache. You need a single, reliable standard to ensure compliance everywhere.

The main international standard is ISO 20471. It has been adopted by many regions, including Europe (as EN ISO 20471). It classifies garments into three classes based on the minimum areas of fluorescent and reflective materials, ensuring different levels of conspicuity for different risk levels.

ISO 20471 is the cornerstone of global high-visibility standards. It was developed to create a universal benchmark for performance, making it easier for multinational companies to source compliant gear. The standard is focused entirely on a garment's ability to signal the user's presence visually. It doesn't just specify colors; it specifies the exact chromaticity and luminance of the fluorescent material to ensure it stands out in daylight. It also details the performance of the retroreflective tape for nighttime visibility. As a global manufacturer, our entire production process is aligned with ISO 20471. Our ISO, OEKO-TEX, and BSCI certifications demonstrate our commitment to meeting this global quality and safety benchmark. This makes Vissafety a reliable partner for businesses operating worldwide.

Conclusion

Ultimately, protecting your team comes down to two simple actions: regular inspection and understanding the rules. Don't rely on a calendar date. Look at the gear itself. Faded fabric, cracked reflective tape, and heavy soiling mean a garment no longer performs its function. This isn't just about looking unprofessional; it means the gear is no longer compliant with critical safety standards like ANSI/ISEA 107 and EN ISO 20471. A worn-out vest is a failed piece of safety equipment. Partnering with a manufacturer who guarantees compliance and provides durable products isn't a cost—it's an investment in your people's safety and your company's reputation.