The Benefits of Using Safety Hard Hat

30 Jun.,2025

 

Hard Hats are Important PPE in the Construction Industry

Protecting workers from potential head injuries is an essential component of any workplace safety program, especially in the construction industry, where a head injury can become life-threatening in an instant.

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Hard hats, if worn properly and consistently, can protect crew members from falling or flying objects, electrical shock hazards and unintentional hard hits against fixed objects.

OSHA Standard .100(a) Employees working in areas where there is a possible danger of head injury from impact, or from falling or flying objects, or from electrical shock and burns, shall be protected by protective helmets.

In order to be effective, hard hats, or protective helmets, must be penetration-resistant, shock-absorbent, water- and fire-resistant. Hard hats must have easy-to-understand instructions provided that explain proper adjustment as well as how to replace the suspension and headband correctly.

Even where there may not be an OSHA requirement to wear head protection, employers may require 100% hard hat use as a company policy. The use of head protection should never be considered a substitute for good safety practices and engineering controls.

Potential job site hazards that may require head protection:

  • Falling, flying or moving objects
  • Electrical shock or burns due to contact with exposed electrical conductors
  • Environments with low overhead or fixed objects like piping, beams, pallet racks, heavy equipment, or inside confined spaces where a worker has the potential to bump their head

Hard hats must be worn when working below other workers who are using tools and materials which could fall.

OSHA rules state that Where falling object hazards are present, helmets (hard hats) must be worn. But that isn’t the only time that a hard hat may be required.

It is important that workers are aware of any possible hazards to their head such as:

  • Falling objects such as parts, tools, packages, boxes, and other stored or racked materials
  • Flying parts or particles from cutting, conveyor, or grinding operations
  • Moving parts, pieces, or objects being handled by overhead lifting equipment such as gantry cranes
  • Striking the front, sides, or top of the head by walking under shelves, racks, pipes, or structures
  • Contact with electrical lines, wires, or energized parts

Make sure your hard hat fits properly! If your hard hat is too large or too small, even if it meets all the requirements, it will not protect you properly. Hard hats must be worn correctly in order to be effective. Hard hats, when fitted correctly, should not bind, slip, fall off or irritate the skin. Some hard hats are designed to fit one size, while others are adjustable. Always follow the manufacturer’s instructions for proper fitting procedures.

Because hard hats are engineered to keep a designed distance between the hard hat shell and the worker’s head, it is important to not add any accessories or liners that are not approved by the manufacturer or compatible with the helmet. OSHA recommends that employers permit only liners that are specifically designed to be compatible with the protective properties of the hard hat. Baseball caps should not be worn underneath hard hats.

Workers need to know that not every hard hat is the same! The type of protection provided by a hard hat can be very different depending on the style and the manufacturer.

Head protection, such as hard hats, must be designed to provide protection from impact and penetration hazards caused by falling objects. OSHA requires hard hats to meet special requirements and be marked with ANSI Z89.1.

Type I hard hats protect from impacts to the top of the head and Type II hard hats protect the top and sides of the head.

There are also three classes of hard hats related to electrical protection.

  • Class G or General hard hats provide some electrical protection
  • Class E or Electrical hard hats provide significant protection from electrical hazards
  • Class C or Conductive hard hats do not provide any protection from electricity

ANSI cautions, “The maximum voltage against which helmets will protect the wearer depends on a number of variable factors, such as the characteristics of the electrical circuit and the equipment involved, the care exercised in maintenance of equipment, and weather conditions.”

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Aluminum hardhats should not be worn in areas where a worker may come in contact with energized circuits.

Protective headgear accessories (like slots for eye PPE or optional brims) can help workers be more comfortable and comply with additional PPE requirements, but keep in mind that hardhat accessories must not compromise the safety elements of the protective helmet.

Before wearing, carefully inspect the hard hat, including all components and accessories, for any signs of damage. Look for dents, cracks, holes due to penetration, or any other damage due to impact, wear, or rough treatment that might reduce the degree of protection originally provided with the hard hat.

A hard hat with excessively worn, damaged, or defective areas should be removed from service. Any hard hat that has received an impact may have a reduced ability to protect a worker and should be removed from service.

During inspection if there are signs that a hard hat has lost the glossy finish, a chalky appearance is beginning to emerge, or the shell is starting to flake away, these may be signs of UV radiation damage, which can cause a hard hat to lose some effectiveness.

Do not store or carry hard hats on the rear window shelf of a vehicle. Sunlight and extreme heat can cause the hard hat to degrade faster, and the helmet can become a flying object hazard in an emergency braking situation.

Do not intentionally drop or throw hard hats, or use them as supports, because damage can adversely affect their level of protection.

Do not alter or modify a hard hat to add accessories unless it’s an approved method provided by the manufacturer.

Remember these important tips when it comes to head protection and hard hats:

  • Always be aware of any possible hazards to your head.
  • Not every hard hat is the same! The type of protection provided can be very different depending on the type of hard hat.
  • OSHA requires hard hats to meet special requirements and be marked with ANSI Z89.1.
  • Workers exposed to electrical hazards must wear the appropriate head protection for the type of electrical hazard.
  • Inspect your hard hat daily for signs of damage.
  • Some hazards to the head may require workers to use hard hats designed for impacts to the sides as well as the top of the head.
  • Workers need training to recognize the types of hazards requiring head protection, how to properly wear and maintain their head protection, and when to replace it.
  • Make sure your hard hat fits properly! If your hard hat is too large or too small, even if it meets all the requirements, it will not protect you properly.
  • Hardhat accessories must not compromise the safety elements of the protective helmet.

PPE - Hard Hat Information | Environmental Health and Safety

Purpose

Hard hats are required when working in areas where there is a potential for injury to the head from falling objects. In addition, hard hats designed to reduce electrical shock are required when working near exposed electrical conductors that may contact the head.

Specialty types of hard hats include those with miner's light attachments, reflective stripe for night work, face shields for welders, and attachments for visors or earmuffs.

Use of Hard Hats

Hard hats should be used when falling object hazards may result from activities with proximity to:

  • persons or operations where accidental dropping or loss of material, tools, equipment or other articles could lead to a head injury;
  • a barricaded or posted demolition or construction area where head hazards exist;
  • objects stored on shelves, platforms, etc. that may fall and cause head injury; or
  • overhead exposed energized conductors nearby.

Hard Hat Design Standards

All hard hats must comply with ANSI Z89.1, American National Standard for Personal Protection - Protective Headwear for Industrial Workers - Requirements. The suspension system inside the hat is designed to help absorb and dissipate impact while keeping a clearance between the head and shell of the hat. The class of hat is usually noted inside the hat shell.

Types and Classes

  • Type 1 - Helmets intended to reduce the force of impact resulting in a blow only to the top of the head.
  • Type 2 - Helmets intended to reduce the force of impact resulting in a blow to the top and the side of the head
  • Class E (Formerly Class B): Helmets for sue where electrical hazards are present (in utility services) that are non-conducting and intended to protect against falling objects and reduce the danger of exposure to high voltage electrical shocks and burns. Offers the highest protection with high-voltage shock and burn protection up to 20,000 volts.
  • Class G (Formerly Class A): General Use (limited voltage - non-conducting) intended to protect against falling objects and reduce the danger of exposure to low voltage electrical conductors. They provide impact and penetration resistance and protection from up to 2,200 volts.
  • Class (Formerly Class C): Class C Hard Hats are not tested for electrical resistance.  They are designed for lightweight comfort and impact protection and are not intended to provide protection from electrical conductors.

Hard Hat Wear Factors and Limitations

Hard hat headbands and chin and nape straps should be adjusted to keep the hat comfortably on the head. Liners or sweatbands can be added for warmth or cooling. The shell or other parts of the hat should be replaced when they become damaged. Clean hats by dipping in hot water with detergent, scrub the shell and rinse in clear hot water. Cleaning solvents may damage the shell.

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