Whether you're at a construction site, cutting timber or logging, working on an oil platform out at sea, or anywhere else the potential for a head injury exists, a hard hat is a critical piece of safety equipment. This makes it extremely important for those who use them to understand the different hard hats available, how to correctly wear and care for them, and the requirements for wearing them on the job.
OSHA standards and regulations mandate specific requirements for head protection, and these rules incorporate standards from the American National Standards Institute (ANSI). While OSHA provides the regulations to follow, ANSI provides the means to follow those regulations. According to OSHA standard 29 CFR 1910.135, a hard hat is required if the following hazardous conditions exist: objects might fall from above and strike employees on the head; employees could potentially bump their heads against fixed objects, such as exposed beams or pipes; or the possibility exists of accidentally making head contact with electrical hazards.
A hard hat that meets the ANSI Z89.1 standard is OSHA compliant, and it defines the classes and types of hard hats for specific hazardous situations; performance and design requirements for penetration, impact, and electrical shock; and testing requirements to ensure a hard hat is OSHA compliant. While it's common that hard hat manufacturers typically test and certify their products, employers need to confirm their choice of hard hats meets OSHA requirements.
A hard hat is specified by both Type and Class; for example Type 1, Class G. The following are ANSI Types and Classes of hard hats and the protection they're designed to provide:
- Type 1: Helmets are intended to reduce the force of impact from a blow only to the top of the head.
- Type 2: Helmets are intended to reduce the force of impact resulting from a blow to the top or sides of the head.
- Class C: Helmets not intended to provide protection against contact with electrical hazards (conductive).
- Class G: Helmets intended to reduce the danger of contact with low-voltage conductors (proof-tested at 2,200 volts).
- Class E: Helmets intended to reduce the danger of contact with higher voltage conductors (proof-tested at 20,000 volts).
To know what standards a particular hard hat meets, ANSI requires markings or permanent labels inside the hard hat. They include the manufacturer's name and date of manufacture; the ANSI standard that the hard hat conforms with, such as ANSI Z89.1-2009; the ANSI Type (Type 1 or 2) and Class designation (C, G, or E); and approximate head size or range for fitting. If the hard hat does list ANSI standard Z89.1-2009 it will include information for Reverse Donning indicating it can be worn forward or backward, a Lower Temperature (LT) designation indicating the hard hat will provide protection at low temperatures down to 22°F, and High Visibility (HV) indicating it meets all requirements for high visibility.
Hard hats have evolved significantly over the years with today's modern hard hat shells made of thermoplastics such as polyethylene, high-density polyethylene (HDPE), or polycarbonate resin. While these advanced materials make for much stronger, structurally sound hard hats, if a hard hat has sustained an impact, dispose of it immediately, whether or not there is any visible damage. Once it's been impacted, the materials of the hard hat could be compromised and weakened so it no longer provides its intended penetration and impact resistance. It's important before each use that a hard hat is inspected visually for damage and signs of fatigue. Inspect for dents, cracks, and gouges or cuts in the shell. Check the suspension for frayed straps, cuts, cracks, or tears in the plastic. Additionally, squeezing a hard hat from each side and listening for cracking or unusual sounds can help determine if it is damaged and should be replaced.
While modern hard hats are durable, they won't last forever. A variety of factors can impact its work life, including frequency of use, environment it's used in, chemical or sunlight exposure, and others. As a general rule, the support strap should be replaced once a year, and the hard hat itself every five years. To prolong its life and keep it looking clean, mild soap and warm water is a good way to clean a hard hat and suspension. Be sure to completely rinse and wipe or air dry it after washing. Using harsh solvents or abrasives on a hard hat is not recommended, even for removing tough-to-remove things like sap or tar. These solvents and abrasives can weaken or degrade the suspension, straps, or the shell itself.
When storing a hard hat, keep it out of direct sunlight and away from high-heat sources such as ovens and furnaces. When exposed to heat, sunlight, or chemicals, the shell may become chalky or have a dull look and become less flexible. If you notice any of this, replace the hard hat shell and/or suspension immediately. While it may be tempting to paint or add stickers to a hard hat, resist that temptation unless it's absolutely necessary. Hard hat shells really shouldn't be painted unless previously approved by the manufacturer. Regarding stickers, self-adhesive, pressure-sensitive, or non-metallic stickers are fine to use with most of today's modern shells. Regardless of what's used, never use stickers or tape to cover up damage on a hard hat.
While hard hats are highly regulated and have to meet stringent standards, it's all necessary to ensure they provide critical safety coverage in demanding conditions for the most important reason: You!
Product Compliance and Suitability
The product statements contained in this guide are intended for general informational purposes only. Such product statements do not constitute a product recommendation or representation as to the appropriateness, accuracy, completeness, correctness or currentness of the information provided. Information provided in this guide does not replace the use by you of any manufacturer instructions, technical product manual, or other professional resource or adviser available to you. Always read, understand and follow all manufacturer instructions.