Is Your Hi-Vis Workwear Putting You at Risk? Here’s When to Replace It

Hi-vis workwear is designed to keep you safe, but if it’s faded, dirty, or damaged, it’s not doing its job. Worn-out apparel reduces visibility, increases the risk of accidents, and may even put you out of compliance with safety regulations. Many workers don’t realize their gear needs replacing until it’s too late. This guide will help you spot the warning signs early and ensure your hi-vis workwear keeps you protected when it matters most.

Signs It’s Time to Replace Your Hi-Vis Workwear

Hi-vis workwear is a key component of workplace safety, helping to prevent accidents by ensuring workers remain visible in hazardous environments. Over time, however, exposure to the elements, repeated washing, and daily wear can degrade its effectiveness.

When hi-vis workwear no longer performs as intended, it puts workers at risk. Whether on a construction site, near road traffic, or in a dimly lit warehouse, reduced visibility can lead to accidents. Regulatory standards, such as ANSI/ISEA 107, establish clear guidelines for acceptable visibility levels. If a garment no longer meets these requirements, it must be replaced to maintain compliance and ensure safety.

Knowing when to replace hi-vis workwear isn’t always obvious. Many workers continue using garments that no longer provide adequate visibility. Below are the key signs that indicate it's time for a replacement.

1. Fading and Dulling of Fabric

Fluorescent colors are essential for daytime visibility, but exposure to UV rays from sunlight can break down the pigments in hi-vis fabric over time. The more time a garment spends outdoors, the faster it fades.

Frequent washing also plays a role. Detergents with harsh chemicals, improper laundering techniques, and high temperatures can strip away color intensity. Even when following washing guidelines, fabric naturally loses vibrancy after repeated cleanings.

A garment that looks faded compared to a newer one may no longer meet safety standards. To assess color brightness, hold the workwear next to a brand-new garment of the same color or test it against our Garment Inspection Card to ensure proper visibility. If the difference is obvious, the older piece should be replaced. 

Work environments with extreme exposure to sunlight, dust, or industrial washing processes may require more frequent replacement of hi-vis clothing. Materials like asphalt, for example, can be especially tough to remove and can coat reflective surfaces, significantly reducing visibility.

2. Reflective Tape Damage

Reflective tape is designed to enhance visibility in low-light conditions, such as early mornings, evenings, or nighttime work. It reflects vehicle headlights and other light sources, making the wearer more noticeable.

However, this reflective material is prone to damage. Cracking, peeling, and fraying occur after repeated bending, washing, and exposure to harsh weather conditions. Workers who frequently kneel, bend, or lean against surfaces may notice faster deterioration in high-contact areas like sleeves, pant legs, and the lower torso.

To check whether reflective tape is still effective:

• Shine a flashlight on the garment in a dimly lit area. If the tape no longer reflects light as strongly as before, visibility is compromised.
• Run your fingers over the tape. If it feels rough, cracked, or begins to peel away, it won’t perform as intended.
• Check for missing sections of tape, as even small gaps can impact visibility.

If the tape shows any of these signs, the workwear should be replaced immediately.

3. Excessive Dirt and Staining

Hi-vis workwear is exposed to dirt, grease, oil, asphalt and other substances that can diminish its effectiveness. Over time, deep-set stains reduce the brightness of fluorescent fabric and can obscure reflective tape, not to mention, it can become a safety hazard if it gets caught in equipment on the job.

Regular washing helps maintain visibility, but some stains are impossible to remove after prolonged exposure. Oil, concrete dust, and chemical spills are particularly difficult to clean and may permanently alter the fabric’s brightness.

If repeated washing fails to restore the garment’s original vibrancy, it may no longer provide adequate visibility. Workers in industries such as construction, waste management, and utilities should inspect their workwear often, as these environments are more prone to staining.

4. Rips, Tears, and Structural Damage

Hi-vis clothing must be in good physical condition to provide effective protection. Ripped fabric, broken zippers, or missing buttons can compromise a garment’s integrity, making it less reliable in hazardous environments.

Small rips or frayed edges might not seem like a big issue at first, but they can grow larger with continued use. Torn fabric in high-movement areas like elbows, knees, and shoulders can lead to garment failure.

Structural damage also affects visibility. If a tear occurs in a section with reflective tape, it creates gaps that reduce overall reflectivity. Workers who rely on their apparel for safety, especially in low-light conditions, should replace any damaged garments immediately.

Download our Guide: The Economic Benefits of Investing in High-Quality Safety Apparel.

5. Age and General Wear

Even if a garment looks intact, natural wear and fabric breakdown can reduce its effectiveness over time. Most hi-vis clothing lasts six months under normal working conditions, but factors like daily use, exposure to extreme temperatures and moisture, and frequent washing with harsh detergents can accelerate deterioration.

To stay compliant and safe, many companies set internal replacement schedules. Workers should regularly inspect their hi-vis apparel and replace it on time, even if there are no visible signs of damage. Some may hesitate to wear new workwear, worrying it makes them look like a rookie on the job, but safety should always come first. If a garment is over a year old and has been used consistently, replacing it is the safest choice, regardless of its appearance.

If a garment is over a year old and has been used consistently, replacing it—or testing it against a Garment Inspection Card to ensure proper visibility—is the safest choice, regardless of its appearance.

Even with proper care, all garments have a lifespan. If you’ve spotted any of the warning signs covered in this guide, it’s time to take action. But how do you know when a replacement is necessary? That’s where Kishigo can help.

How Kishigo Can Help

Worn-out hi-vis workwear puts your safety at risk. Don’t guess, know for sure. Kishigo’s Garment Inspection Card makes it easy to check brightness and reflectivity, so you can replace workwear before it fails you.

Our high-quality, ANSI/ISEA 107-compliant apparel is built for durability and maximum visibility. Stay safe, stay seen, and stay compliant. Order your Garment Inspection Card today or contact our team for expert guidance.