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👷 Hard Hat Safety

Topic: Hard hat types, proper fit, inspection, and replacement Duration: 5–8 minutes Standard: OSHA 29 CFR 1926.100 — Head Protection; ANSI/ISEA Z89.1

The Stats​

  • Struck-by hazards cause approximately 75,000 head injuries per year in construction
  • Hard hats reduce the risk of serious head injury by 80%
  • A 2-lb wrench dropped from 50 feet hits with 100+ lbs of force
  • Head injuries that could have been prevented by a hard hat cost employers an average of $70,000 per incident

Your hard hat is the only thing between your skull and a falling hammer.

Hard Hat Types​

TypeProtectionWhen Required
Type ITop of the head only (straight-down impacts)Standard construction — most common
Type IITop and sides (off-center and lateral impacts)Work near swinging loads, steel erection, confined spaces

Know what your project requires. Some GCs and owners now require Type II across the entire site.

Hard Hat Electrical Classes​

ClassProtectionUse
Class E (Electrical)Up to 20,000 voltsElectrical work, work near power lines
Class G (General)Up to 2,200 voltsGeneral construction
Class C (Conductive)No electrical protectionNot for construction — vented, no insulation
Class C Hard Hats Have No Electrical Protection

Vented hard hats (Class C) should not be used on construction sites where electrical hazards exist. If your hard hat has ventilation holes, it is Class C and does not protect against electrical contact.

Proper Fit and Wear​

Fitting Your Hard Hat​

  1. Adjust the suspension so the hat sits 1 inch above your eyebrows
  2. Adjust the headband for a snug but comfortable fit
  3. The suspension should maintain a 1–1¼ inch gap between the shell and your head (this gap is what absorbs impact)
  4. The hard hat should not rock, slip, or fall off when you bend over

How to Wear It​

  • Brim forward (unless the manufacturer specifically approves reverse wear)
  • Chin strap required when working at heights, in high wind, or when looking up
  • Nothing between the hat and your head that the manufacturer hasn't approved
  • Winter liners — use only manufacturer-approved liners that don't interfere with the suspension

Inspection — Before Every Shift​

Shell Inspection​

  • No cracks, dents, or holes
  • No chalking, flaking, or fading (UV damage)
  • No signs of chemical exposure (softening, swelling, discoloration)
  • No burns or heat damage
  • No modifications (holes drilled, paint, stickers covering damage)

Suspension Inspection​

  • Straps not frayed, torn, or stretched
  • All attachment points connected
  • Headband adjusts properly
  • Suspension maintains proper clearance (1–1¼ inch) between shell and head
  • Sweatband clean and in good condition

If any inspection item fails — replace the hat or component immediately.

When to Replace​

ConditionAction
After any impact (even if no visible damage)Replace immediately — internal damage may be invisible
Visible cracks, dents, or penetrationReplace immediately
UV damage (chalky, faded, brittle)Replace immediately
Chemical exposure (paint thinner, solvents, etc.)Replace immediately
Suspension worn or damagedReplace suspension (or whole hat if unavailable)
Every 5 years (shell)Replace regardless of appearance
Every 12 months (suspension)Replace the suspension system
The Bend Test

Hold the brim and press inward on the shell. If it cracks, flexes unevenly, or doesn't spring back — replace it. A healthy shell springs back immediately and makes no cracking sounds.

What NOT To Do​

❌ Never drill holes in your hard hat (destroys structural integrity and voids ANSI rating) ❌ Never paint your hard hat with non-approved paint (solvents can weaken the shell) ❌ Never store your hard hat in direct sunlight long-term (UV damage) ❌ Never use it as a bucket, stool, or knee pad ❌ Never wear a ball cap under the hard hat (lifts the hat, defeats the suspension gap) ❌ Never wear a damaged or expired hard hat — "it's better than nothing" is a myth (a cracked hat can shatter on impact and cause worse injury) ❌ Never share hard hats without sanitizing and adjusting the suspension

Stickers and Accessories​

  • Stickers are generally OK if they don't cover damage and are placed per manufacturer guidelines
  • Pressure-sensitive stickers only — never use solvent-based adhesives
  • Don't cover more than 50% of the shell surface — you need to see the shell for inspection
  • Headlamps, face shields, and ear protection — use only accessories designed for your specific hard hat model

Discussion Questions​

  1. What type and class of hard hat does this project require?
  2. When did you last replace your hard hat shell? Your suspension?
  3. Has anyone ever had a hard hat save them from an injury?
  4. Grab your hard hat right now — inspect it. Does anything need replacement?

Today's Commitment​

"I will wear my hard hat properly at all times on site, inspect it before every shift, and replace it when damaged or expired."

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