In brief
High-visibility clothing has two components: the fluorescent background that makes you noticeable in daylight and the retroreflective tape that reflects headlight beams back. EN ISO 20471 defines three classes according to the minimum area of these two materials; a vest on its own reaches class 2 at most. The risk assessment determines which class is used in which area; visibility lost through washing and wear is monitored with regular checks.
When does a reflective vest work?
For a forklift driver to notice you, two things are needed: you must stand out from the background in daylight, and in the dark you must reflect the headlight beam back to them. An ordinary orange T-shirt partly achieves the first and does not achieve the second at all. A reflective vest and other high-visibility clothing meet these two functions with two different materials:
- Fluorescent background material: In daylight and at dusk, it looks brighter than its surroundings. EN ISO 20471 defines fluorescent yellow, fluorescent orange-red and fluorescent red.
- Retroreflective tape: Reflects light back in the direction it came from. In the dark, when a headlight or torch beam strikes the tape, the driver sees the worker from a distance.
For a hi-vis vest to work, these two materials must be of sufficient area, in the right place and clean. In this article we explain the classes, the rules for use in warehouse and logistics areas and how to track visibility lost through washing.
High-visibility classes: EN ISO 20471
For professional use, high-visibility clothing is manufactured to standard EN ISO 20471. The standard defines three classes according to the minimum area of fluorescent and retroreflective material on the garment:
| Class | Fluorescent background (minimum) | Retroreflective tape (minimum) | Typical garment |
|---|---|---|---|
| Class 1 | 0.14 m² | 0.10 m² | High-visibility trousers, parts of overalls with tape |
| Class 2 | 0.50 m² | 0.13 m² | Vest, sleeveless jacket |
| Class 3 | 0.80 m² | 0.20 m² | Jacket with sleeves, or a jacket and trouser suit |
For class 3, the garment must cover the torso and have sleeves with tape or long trouser legs with tape. This is why a vest alone cannot be class 3; class 3 is achieved either with a jacket with sleeves or by wearing a class 2 vest together with class 1 trousers. The class achieved by a combination is stated on the garment's label. The number next to the pictogram on the label shows the garment's class; because the area shrinks in smaller sizes, not every size of the same model may be in the same class.
Which class in which area?
Under Art. 7 of the Regulation on the Use of Personal Protective Equipment at Workplaces, the employer determines which protective equipment is used in which job based on the results of the risk assessment. The regulation does not fix the high-visibility class by type of workplace; your risk assessment makes the choice. In practice, the following approach works well:
| Work area | Main risk | Recommended minimum choice |
|---|---|---|
| Well-lit indoor warehouse, low-speed forklift traffic | Blind corners, meeting between racks | Class 2 vest |
| Loading dock and open yard | Lorry manoeuvres, variable light | Class 2 vest; class 3 at night and in bad weather |
| Roadside within an OIZ, entrance gate, car park | Fast vehicle traffic | Class 3 |
| Night shift outdoor work | Darkness, headlights | Class 3, with tape also covering arms and legs |
Before choosing, check whether engineering measures are in place: is the lighting sufficient, is the pedestrian walkway physically separated, is there a mirror at the blind corner? The vest does not replace these measures; it complements them. For the order of measures, see our article on the hierarchy of controls.
The vest rule in forklift areas
A rule commonly found in warehouses and logistics centres in Bursa and the surrounding provinces is the sentence "everyone entering the forklift area wears a vest". The rule is right, but for it to work on site the details must be written down:
- Who wears one? Pedestrian workers entering forklift routes, dispatch and quality staff, the maintenance team, visitors and lorry drivers getting out of their vehicles.
- Do drivers wear one too? When a forklift driver gets out of the vehicle and walks around the area, they count as a pedestrian; wearing it in the vehicle too covers the moments when they step out.
- Colour coding: Giving visitors and loading banksmen vests of a different colour lets everyone on site see at a glance who is doing what. Annex 9 of the Regulation on Health and Safety Signs also requires the signaller to wear brightly coloured distinctive clothing reserved for signallers.
- Entry point: Vests are ready on a rack at the entrance to the area; the excuse "I forgot" disappears.
- Enforcement: The shift supervisor and the specialist carrying out the site walk have the authority to remove a pedestrian without a vest from the area.
A vest does not replace a traffic plan. We explained how to separate forklift and pedestrian routes in our article on the forklift and pedestrian traffic plan in the warehouse, and the dock side in our article on loading dock safety.
Night work clothing: where the retroreflective tape goes
In night work clothing, the effect of the fluorescent colour decreases and the job is left to the retroreflective tape. Three rules increase the tape's effect:
- The tape should encircle the torso. Tape that cannot be seen from the front and back does not protect against a vehicle approaching from the side.
- Arms and legs should have tape. Tape on moving arms and legs makes it easier for a driver to recognise the person ahead as a human being.
- The tape should not be covered. In winter, a coat, raincoat or belt worn over the vest covers the tape. In cold weather, choose a coat or raincoat with reflective tape, or have the vest worn on top; details are in our article on protective clothing in cold and wet weather.
Washing, wear and replacement criteria
High-visibility clothing can lose its class with use. The fluorescent colour fades with sunlight and washing, and the tape cracks, peels or loses its reflective properties when oil and dust stick to it. If the label states the maximum number of washes for which the garment retains its properties, track this number in the issue record.
Use this checklist to decide on replacement:
- The fluorescent background looks faded, grey or dirty.
- The retroreflective tape is cracked, broken or lifting.
- When viewed with a torch in a dark area, the tape does not reflect brightly.
- The garment is torn, its seams have opened, or a patch, logo or label covering the tape has been added.
- The maximum number of washes on the label has been reached.
A garment meeting any of these criteria is replaced. You can also use the table in our article on PPE issue and replacement tracking for vests. The regulation requires PPE to be checked before each use and faulty PPE not to be used until the fault is remedied (Art. 8/3).
Purchasing and the employer's obligations
Under Art. 6 of the PPE Use Regulation, PPE must be appropriate for the risk, must not itself create additional risk, must be ergonomic and must fit the wearer. For a vest, this means: the size must be chosen correctly, hanging cords and hook-and-loop sections must be assessed for those working near machinery, and breathable fabric should be preferred in hot environments. When purchasing, check the CE marking, the EN ISO 20471 label, the class and the supplier's declaration of conformity.
Common mistakes on site are:
- Buying one size: The same size vest is bought for everyone; a large vest hangs loose and catches in machinery, and a small vest cannot be worn over a jacket.
- Adding logos and text: A company logo or name print reduces the fluorescent area; agree the print area with the supplier so that it does not lower the class.
- Vest worn open: In a vest worn open at the front, the continuity of the tape encircling the torso is broken.
- Shared visitor vests not being cleaned: A dirty vest creates a hygiene problem and loses its reflective properties.
The employer also informs workers about the risks the PPE is used against and ensures that training on its use is provided (Art. 6/1-f, g). The cost of PPE cannot be passed on to the worker. At Bursa Sistemer, in our OHS specialist service, we review warehouse traffic on site and write the vest rule together with the traffic plan; you can find other risks specific to the logistics and warehousing sector on our sector page. You can add the annual PPE renewal calendar to the OHS calendar tool.
Frequently Asked Questions
Are a reflective vest and a hi-vis vest the same thing?
In everyday language they are used interchangeably. What matters is not the name but that its label states a class under EN ISO 20471. Promotional vests with no stated class should not be used as PPE at work.
Does a forklift driver need to wear a vest?
When the driver gets out of the vehicle and walks around the area as a pedestrian, they face the same risk as other pedestrians. It is therefore recommended that the rule also covers drivers, i.e. that the vest is worn inside the vehicle too.
After how many washes is a vest replaced?
There is no fixed period. If the label states a maximum number of washes, that number applies; in addition, if fading, tape damage or weak reflection in the torch test is seen, it is replaced regardless of the number.
Is it mandatory to give visitors a vest too?
If a visitor enters an area with forklift or vehicle traffic, the measure set for pedestrians in the risk assessment also applies to the visitor. Issuing a visitor vest of a different colour at the entrance is a practical solution.
A certified specialist matched to your hazard class: site inspections, approved logbook, training plan, annual plan and report follow-up.
Bursa SİSTEMER OSGB Technical Team — written from the field experience of our OHS specialists and workplace physicians. Legal information is valid as of the publication/update date; contact us for an assessment specific to your business.