Hard Hats: 100 Years of Evolution

Head Protection Is Top Priority

There is no shortage of ways to get injured on a construction site, which is why we have so many PPE options. Hard hats are the first line of defense against falling objects, tools and debris, fixed objects such as pipes, and electrical hazards. And there is nothing more important than protecting your head. Hard hats are ubiquitous on jobsites, and everyone working on a construction site, or even visiting, should have the right protection on their heads.

Hard Hat History

Hard hats have been around for over 100 years. Shipbuilders used to cover their hats with tar to harden them and create a layer of protection. These early hard hats protected dock workers from tools and objects falling from ships. Other types of safety style hats were originally made of leather or steel, and in 1919, protective hats were being made of steamed canvas, glue and black paint.







As construction projects grew larger in scope and scale in the 1930s and 1940s—think Hoover Dam, Golden Gate Bridge, New York City high rises—companies began requiring employees to wear hard hats and they became the construction mainstay we know today.

Over the years hard hats have been made of aluminum, fiberglass and plastic; today, most hard hats are composed of polyethylene and include ventilation. There are optional accessories for today’s modern hard hats like face shields, ear muffs, visors and perspiration liners, and you can attach lights, music players or two-way radios to many of them. Hard hats have come a long way since the days of pouring a heavy layer of tar over a standard hat. And, they continue to evolve with the development of additional accessories and a shift toward an increased use of safety helmets.

Ratings

Like all Personal Protective Equipment (PPE), OSHA regulations require the use of American National Standards Institute (ANSI) compliant head protection (ANSI Z89.1-2014). And OSHA rule (29 C.F.R. 1926.100) states that employers must provide head protection equipment that meets or exceeds the industry consensus standard ANSI Z89.1.

Hard hat classification is referred to by their Type and Class.


There are two types of hard hats:


The three classes of head protection include:


Therefore, a Type 1, Class C hard hat would be the standard worn by a construction worker not exposed to electrical hazards. An electrician would more than likely wear a Type 1, Class E hard hat.

Styles

Hard hats come in many styles. The two most popular are the Cap style which has a front brim with a rolled edge (allowing water to drain off the bill); and the Full Brim style which is a wider brimmed hat.






Manufacturers recommend against drilling holes or even painting hard hats, as these can degrade the plastic and render the hat less effective. It is ok to slap stickers on them and stickers can sometimes be a form of self-expression on the job site. In a sea of matching Hi-Viz vests and coveralls, sometimes a stand-out hard hat is the best way to differentiate workers.

Accessories

While a stock hard hat may not come with many accessories, there are many add-ons that make typical hard hats more comfortable and effective.

Suspension

One thing the old timers didn’t have in their hard hats was a suspension system. These days hard hats contain suspension under the plastic that absorbs the force of impact and further protects the worker underneath. The suspension straps sit between the inside of the helmet and the top of the head. They come with either 4, 6 or 8-point suspensions. The number of points represent the connections between the suspension and the shell; the greater number of points maximizes stability and comfort.

Suspensions are adjustable and come in the following three forms:

When is it Time to Get a New Hard Hat?

While there are no hard and fast guidelines on when to replace a hard hat, standard hard hats can last up to five years. Accessories like liners, sweatbands and straps should be replaced once a year. Workers who wear hard hats daily should inspect them on a regular basis. Encourage the crew to conduct frequent checks on their own hard hats; checking the straps and suspension for any wear and tear. Suspension systems can and should be replaced when the straps are frayed or damaged.

Hard hats should be inspected prior to every use. Any visible damage (such as dents, cracks, gouges or penetration of the shell) or a failed inspection, warrants the purchase of a new hard hat.