Did you know that a hard hat is only effective when it is worn correctly? That marking a hard hat with stickers or penned writing could affect its crystalline structure thereby causing an issue with the integrity of the shell, or that hard hats have an expiry date and should be stored correctly in a cool place? Through my many years working in industry, it became clear that most people don’t know these facts, as time and time again I saw workers either not wearing head protection, or not wearing and caring for it correctly.
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Another thing that stuck with me is that I have seen workers and some companies pay around 10 times more for a pair of branded safety boots than they would pay for a hard hat. Yet our head contains our brain which powers the rest of our body and if an injury means it is not working properly, our lives would not be the same. Clearly, although hard hats had been around for years, they were not being managed properly, and there would be more serious injuries unless something changed.
Marking a hard hat with stickers or penned writing could affect its crystalline structure thereby causing an issue with the integrity of the shell
It was at this point that I decided to launch an awareness campaign to address the matter; one that would culminate in an annual week-long event designed to highlight the need for industrial workers to wear head protection, and to maintain it properly. The campaign would cover all aspects of head protection including training and wear and care, but most of the initiatives would be aimed at raising awareness of head injuries to help people understand that, if you damage your head, the injury you sustain could be devastating and may have a profound effect on your life, as well as the lives of those around you.
Hard Hat Awareness Week came to fruition. Originally scheduled for June, like so many plans in the event had to take a back seat as whole countries found themselves in the grip of the Covid pandemic and almost everyone was plunged into compulsory lockdowns and most industries were focused on respiratory protection. The campaign week was pushed to September yet was a resounding success with plenty of activity. While active in Dubai, it was first launched in the UK before drawing participants across Europe and the US. Then, as the world started opening up, the event became bigger and better, with industries joining the cause helping to spread awareness.
Now, Hard Hat Awareness Week is in its fifth year and is still growing. During the course of the campaign we work very closely with our primary partner, Headway, a brain injury charity based in the UK, and supporters including PPE supplier Arco, and head safety technology developer Mips, to raise awareness of the various aspects of head injuries, for instance, increasing understanding of angled impacts which can result in a rotational injury. This is exceptionally important to know as currently, within the standard, only linear impacts are addressed and only the crown of the helmet is tested against dropped objects. However, helmets do exist on the market that can provide protection against rotational injuries and similar issues. Another crucial goal is to raise awareness of concussion which can occur after an impact even if the person is wearing a helmet. But concussion is only a symptom and there may be further problems, so it is vitally important to seek medical advice when anyone is involved in an incident.
“Standards are the minimum requirement but we should be going for gold when protecting heads”
But as well as spreading awareness, the event also aims to increase injury prevention. A big part of head injury prevention is knowing your stuff – knowing the difference between types of head protection and which activities they’re suitable for, the materials they are made from, the standards they’re tested to, and how those standards are changing. And it can also help to examine real-life impact scenarios and rotational injuries, to understand how you can prevent them from occurring.
Hard hats are a common PPE item but they offer far more than people realise in terms of protection. However, while it should be simply part of the normal process to check what type of head protection you need for a specific activity, it is wise to remember that meeting official safety standards is simply ‘good’. Safety standards represent a minimum requirement so all buyers should be going for gold when it comes to protecting heads, and aiming far above the bare minimum. Education is also a key ingredient to help people to understand head injuries and empower them to make the best choices in their protection.
Worker safety can be divided into four key areas:
1. The evolution of worker head protection: The fascinating history of hard hats, showcasing how safety equipment has continuously improved and the journey to modern designs
2. The realities of safety testing: The limitations of testing processes, highlighting how and why laboratory environments often differ from real-world working conditions
3. Empowering workers to protect themselves: Equipping workers with knowledge to choose the best protective gear for their specific tasks, and
4. Informed procurement: Guidance for managers and procurement teams to make optimal decisions when selecting safety equipment.
1. The evolution of worker head protection
Safety helmets and hard hats have been protecting people in one form or another for thousands of years. Records of wearing head protection go all the way back to battle armour in BC, and large-scale batch production in the 900 BC as forged coverings of iron or bronze were used to protect soldiers from arrows, axe and sword blows. In later years, many workers wore tough woven cloth caps, until early modern times, around the late s, when a little-known company called The Patent Pulp Manufacturing Company (which is today Centurion Safety Products) produced a cap made from pulp-lined steel to protect people when travelling.
Use of helmets became more widespread alongside major engineering and construction projects. Like in , when a US Navy shipyard commissioned a shipyard safety helmet, and in the years that followed, mentions of workplace head protection increased, but these items were mainly made of steel and aluminium, due to it being lightweight. In and respectively, Bullard’s invention of the ‘hard boiled’ leather hat offered a lighter option and they were used by construction workers on projects including building of the Hoover Dam and the Golden Gate Bridge.
Thermoplastic injection did not begin until the early s, but by then standards had been introduced, based on Sir Hugh Cairns’ paper, ‘Head injuries in motorcyclists: the importance of the crash helmet’. These standards were introduced to govern requirements for head protection, enabling workers to buy products with confidence knowing they complied with certain requirements. One of the first of these standards was BS The Light Duty Safety Helmet standard and was the forerunner of all industrial safety helmet or hard hat standards.
Today, hard hats and safety helmets provide a very good level of protection, according to current standards. But, as previously stated, a standard level of safety should be the bare minimum and one should always aim for maximum protection. To help workers and buyers assess if their head protection is good enough, this year’s Hard Hat Awareness Week will promote a back-to-basics safety culture, and will ask:
• Are you wearing the right head protection for the tasks you are completing and the environment you are working in?
• Are you wearing the head protection correctly?
• Is your head protection stored and maintained correctly?
• Is your head protection in date and certified?, and
• Is your head protection comfortable for extended periods of wear?
2. The realities of safety testing
While rigorous testing ensures a certain level of protection, limitations do exist, including:
• Controlled environments. Testing typically takes place in controlled labs with standardised drop tests performed only in a linear fashion; however, real-world scenarios involve unpredictable angles and forces of impact, which was recently demonstrated in studies conducted by several researchers, including Imperial College London. This suggests standards should be revised to reflect real-world incidents more closely.
• Material degradation. Environmental factors such as extreme temperatures, UV radiation, and chemical exposure can degrade materials over time, compromising the integrity of head gear. While some testing is done for this it may not match real-world exposure, which may impact a hat's effectiveness.
• User error. Improper fit or neglecting to wear a hard hat correctly can significantly reduce its protective capabilities. This is commonplace in industry, and more should be done to promote a back-to-basics safety culture.
3. Empowering workers to protect themselves
Workers play a crucial role in their own safety. They can make informed choices by:
• Understanding risk assessments. Employers have a legal obligation to conduct risk assessments for various tasks. Workers should actively engage in understanding these assessments and the identified risks.
• Knowing the standards. Workers should familiarise themselves with relevant safety standards for industrial safety helmets. This standard is for industrial helmets and contains the tests that are conducted for the appropriate applications.
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• Consulting safety specialists. Workers and buyers or procurement should not hesitate to seek guidance from safety officers or experienced colleagues regarding the best hard hat to choose for specific tasks.
4. Informed procurement
Managers and procurement teams have a significant responsibility in selecting the right equipment for workers. To prevent and reduce injuries among workers, they should:
• Prioritise safety over cost. Buying for the cheapest option can be a false economy. Procurement should invest in high-quality hard hats that exceed required safety standards.
• Consider ergonomics. A comfortable hard hat is more likely to be worn correctly. Remember that this piece of PPE often gets worn for extended periods of time so it is better to choose wisely to ensure proper wear at all times.
• Maintenance. Hard hats must be maintained and stored correctly to ensure they are fit for purpose. Employees should be encouraged to look after their head gear as it may one day save their life.
While this is a good practical basis for managing head protection, it is by no means an exhaustive list. There are
many additional aspects to take into consideration. For instance, there’s the need to provide proper worker training on the selection, fitting and maintenance of hard hats; to carry out regular inspections of hard hats to check for any cracks, dents, or signs of wear and tear because damaged hard hats should be replaced immediately; and promotion of a culture of safety because both employers and employees will benefit from fostering a workplace environment where prioritising safety is encouraged.
But it’s more than that, even. Worker safety is a shared responsibility. By understanding the history of worker protection and how it is evolving, the limitations of safety testing, and empowering both workers and management teams, it’s possible to create safer work environments and prevent injuries. Remember, investing in proper safety equipment and fostering a safety-conscious culture is not just an expense: it is an investment in workforce wellbeing. And of course, it’s important to take part in informative events, like Hard Hat Awareness Week, where we encourage people to boost their knowledge and also open up more opportunities to communicate about safety concerns and solutions. We welcome participation from all who have a personal stake in protecting their head so I urge everyone not only to get informed and involved, but also to celebrate the existence of the humble hard hat.
Author
Chris Tidy is the director of Specialist Training & Consulting Company (STTC) and the founder of Hard Hat Awareness Week.
Looking for the perfect safety helmet for your construction work? This guide makes it simple. We’ll help you identify the right helmet by covering key features like materials, comfort, and compliance with safety standards. Plus, you’ll discover practical tips for making the best choice based on your job needs.
By the end, you’ll have all the information you need to confidently choose the ideal helmet—and we’ll even guide you on the next steps to enhance your safety with additional protective gear. Let’s get started!
For a broader look into head protection, visit our main article on Hard Hats and Safety Helmets: Selecting The Right Headgear.
Choosing the right construction helmet requires careful consideration of several critical features to ensure both safety and functionality. For instance, workers in demanding environments might prioritize helmets with enhanced impact resistance.
Safety helmets are typically made from polycarbonate, ABS plastic, or fiberglass, each offering varying levels of durability and resistance to impact. For areas requiring enhanced protection, helmets made of fiberglass or polycarbonate are ideal due to their superior strength and reliability.
A well-fitted helmet enhances comfort and ensures maximum efficiency during work. Look for:
Ensure the helmet complies with relevant standards, such as those defined under European regulations, which specify requirements for industrial safety helmets.
Check the certification label or manufacturer’s specifications for compliance. Learn more about EN Standards from this guide in Wikipedia.
Modern safety helmets come with features like:
For a detailed look into additional features, see Choosing The Best Headlamp For Work.
Construction jobs vary, and so do their safety requirements. Below are common types of helmets:
For more on choosing electrical helmets, check out Safety Helmet vs Hard Hat.
Follow these steps for an effective selection process:
To ensure long-term protection:
Regular replacement of helmets every 3-5 years, as per manufacturer guidelines, helps maintain their protective effectiveness. Always check the manufacturing date to ensure you’re purchasing a helmet with maximum potential lifespan.
Browse a wide range of high-quality hard hats and safety helmets to find the perfect fit for your needs. Pair your purchase with accessories and related PPE to ensure comprehensive safety.
While safety helmets are vital, pairing them with additional PPE can address other site-specific risks, such as hand protection with gloves or enhanced visibility with reflective clothing:
We hope this guide has provided valuable insights into selecting the best safety helmet for construction, from understanding key features to meeting industry standards. Whether you’re safeguarding yourself against falling objects or ensuring compliance with workplace regulations, we’re here to support your safety journey.
Explore our full range of Safety Helmets on Droppe, featuring trusted brands known for quality and reliability.
For further insights, check out our guide to Hard Hats And Safety Helmets and related articles.
Need help or advice to find the perfect helmet? Reach out anytime—we’re here to ensure your confidence and protection with every choice.
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