Hardhats may be hot and uncomfortable in summer, but they can mean the difference between suffering a mild concussion or permanent brain damage. They also can prevent cranial punctures from metal, wood, or glass.
Many workers, however, don’t realize that hardhats wear out. As a general rule, most manufacturers recommend replacing them every five years, and some recommend replacing the suspension webbing every 12 months. Hats exposed to higher temperatures, sunlight, or chemicals should be replaced every two years. Most hardhats have manufacture date codes molded on the underside brim, but their life span begins the day they go into service.
A fall of 8 to 10 feet can compromise the effectiveness of hardhats. They are designed to protect workers only once. After a forcible blow of any magnitude, even if no damage is visible, the hat must be replaced.
Manufacturers also recommend inspecting hardhats before and after each use. Examine the shell for dents, cracks and gouges, and check whether it is stiff or has become brittle. Check if the surface is faded or dull, or has a chalky appearance. All are signs of damage or that the life span has expired. In that event, replace it immediately. Don’t try to repair cracks with adhesives, as they do not possess dielectric (nonconductor of electric current) or impact properties.
Field testing
A simple field test can determine possible degradation. Compress the shell inward from the sides about one inch with both hands, then release the pressure without dropping the hat. It should quickly return to its original shape, exhibiting elasticity with no residual deformation. Compare the elasticity of the used hat with a new one. If they aren’t similar, or if the old hat cracks, replace it.
The energy-absorbing suspension system must be inspected, too. Replace the webbing when it becomes brittle, if one or more of the mounts break, the webbing no longer holds securely to the head, the headband or size adjustment slots are torn, or the cradling straps are cracked, frayed, or broken. Perspiration, hair oils, or normal wear can cause these conditions.
The daily inspection should include adjusting the headband to compensate for hair growth or a haircut. Depending on the brand, keep one inch of space between your head and the shell to allow the suspension system to move and circulate air to cool the scalp. A hat fits properly if it stays on when workers bend over, but doesn’t leave a mark on the forehead. If the webs are too tight, the force of a blow is absorbed by the head and neck.
Although most manufacturers add an ultraviolet inhibitor, exposure to direct sunlight is the quickest way to degrade the shell. Workers should never store hardhats in the rear window or on the dash of a vehicle. (Such storage also creates the possibility that the hat could become a missile during a panic stop.)
Maintenance
Dirt and grime can hide defects. Hardhats can be cleaned with warm water and mild detergent, or by using a damp towel. Check the manufacturer’s instructions on how to remove tar and other resistant materials. The webbing can be cleaned similarly. The sweatband in the front or back of the hat can be washed gently by hand, but probably won’t last as long as the hardhat. Universal replacement brow pads are available.
Hardhat maintenance includes the following precautions:
• Never alter or modify the shell or suspension, as that can drastically reduce the protection provided.
• Never drill holes in the shell for ventilation.
• Never use a suspension not intended for a particular shell or made by a different manufacturer.
• Never carry or wear anything between the suspension and the shell. A ball cap or other object may limit the clearance necessary for the energy absorption system to work properly. An object may contain metal parts that may diminish the hat’s dielectric protection. Some products, such as winter liners and sunshades, are designed to work with hardhats. Follow the manufacturer’s recommendations for these products.
Self-adhesive stickers have become common as workers personalize their hardhats for marketing or identification purposes. The adhesive used in typical pressure-sensitive stickers doesn’t affect the shell under normal conditions.
However, stickers should be applied at least 3/4 inch away from the edge of the hat to prevent them from possibly acting as conductors between the outside and inside of the shell if they were to wrap around the brim. Stickers should be kept to a minimum so as not to interfere with regular inspections.
Increasing demands on safety directors may lead them to assume that workers understand head protection requirements. However, experts recommend covering hardhat safety and maintenance two to three times a year in toolbox talks.
