SAINT MICHAEL’S COLLEGE ONE WINOOSKI PARK, BOX 260
DON’T BE HARD-HEADED – BE HARD HATTED
Many employees in construction wear hard hats.
Some take them for granted or misuse them.
Others grow fond of them. Do you know a co-
worker whose hard hat has seen better days? Next
time you see them; ask him or
her if they’ve thought about
replacing that
well-worn hat.
You just might
save a life.
Head protection standards
OSHA 29 CFR 1926.100(a) states “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.”
OSHA 29 CFR 1926.100(b) states “Helmets for
the protection of employees against impact and
penetration of falling and flying objects shall
meet the specifications contained in American
National Standards Institute (ANSI), Z89.1-
1969, Safety Requirements for Industrial Head
Protection.”
Employees exposed to high-voltage electrical
shock and burns must meet the requirements
found in ANSI, Z89.2-1971, Safety Require-
ments for Industrial Protective Helmets for Elec-
trical Workers.
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COLCHESTER, VERMONT 05439
Revised American National Standards for Head
Protection – ANSI Z89.1–2003
To keep employees safe and comply with various
government standards, starting with OSHA regu-
lations, employers must be knowledgeable about
both the range of potential hazards and the types
of safety equipment needed. Fortunately, along
with continuous technological improvements in
materials and design, every year brings new safety
products. Though OSHA still references Z89.1 –
1969, you have to meet the most current ANSI
standard.
ANSI Z89.1-2003 Standard, Occupational and
Educational personal Eye and Face protection
devices, which was approved by ANSI’s Board of
Standards Review on June 19, 2003 is now avail-
able for purchase. This standard provides per-
formance and testing requirements for industrial
helmets. It is a revision of ANSI Z89.1-1997,
which established the types and classes of protec-
tive helmets, depending on the type of hazard
encountered.
The revised standard features strengthened
impact-resistance requirements, yet allows for
advancements in technology and science.
In 2009 the ANSI Z89.1-2008 standard will be
implemented. In addition to the required ele-
ments such as dielectric, impact and penetra-
tion protection, the ANSI/ISEA Z89.1-2008 re-
vision will contain optional criteria for charac-
teristics such as reverse donning, high-visibility,
and extreme temperature exposure.
To learn more go to www.safetyequipment.org
Head hazards
Head injuries are caused by falling or flying
objects, or by bumping the head against a fixed
object. Head protection, in the form of hard hats,
must do two things: resist penetration and ab-
sorb the shock of a blow. This is accomplished by
making the shell of a material hard enough to
resist the blow, and by utilizing a shock-absorbing
lining composed of headband and crown straps
to keep the shell away from the wearer’s skull.
Hard hats are also used to protect against electri-
cal shock.
The requirements of the 2003 standards for hard
hats fall into two types and three classes:
• Type 1 — Hard hats intended to reduce force
of impact resulting from a blow only to the top
of the head.
• Type 2 — Hard hats are intended to reduce the
force of impact resulting from a blow which
may be received off center (lateral) or to the top
of the head.
• Class E — (Electrical) are tested to withstand
20,000 volts.
• Class G — (General) helmets are tested for
2,200 volts.
• Class C — (Conductive) provide no electrical
protection.
All hard hats that meet the ANSI standard will
be labeled on the inside of the hat. All hard hats
must meet the ANSI Z89.1-2003 standard.
How to wear a hard hat
The hard hat will only work if worn properly.
• Adjust headband size so that headwear will stay
on when the wearer is bending over, but not so
tight that it leaves a mark on the forehead.
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• Do not put anything between the suspension
and the shell. There must be clearance inside
the headwear while it is being worn. In case of
a blow to the head, that space helps absorb the
shock.
• Adjust the suspension so there’s 1¼ inches be-
tween the top of your head and the shell. (If
the manufacturer’s directions are different, fol-
low those.)
Inspection and Maintenance
A typical helmet consists of two components:
shell and suspension. These components work
together as a system. It is important for both the
shell and suspension to be inspected on a regular
basis.
Proper care of hard hats is important. Certain
requirements must be followed:
• Check the hat daily for signs of dents, cracks or
penetration. Do not use it if any of these signs
are found on the shell, suspension, headband,
or sweatband.
• Protect the hat from heat and light. Do not
leave your hat on the rear-window shelf of a
vehicle or in direct sunlight.
• Clean the hat at least once a month in warm,
soapy water. Scrub and rinse the shell with
clear, hot water.
• Maintain the integrity of the hat. Do not paint
it; some types of paints and thinners may dam-
age the shell or weaken the hard hat.
• The hard hat can be tested by compressing the
shell inward from the sides about an inch, us-
ing both hands, and releasing pressure without
dropping the shell. The shell should quickly re-
turn to its original shape, exhibiting elasticity.
If the shell does not exhibit elasticity similar
to that of a new shell, it should be replaced
immediately.
When to Replace Hard Hats
Hard hats with any of the following defects
should be removed from service and replaced:
• Perforation, cracking, or deformity of the brim
or shell;
• Indication of exposure of the brim or shell to
heat, chemicals or ultraviolet light and other
radiation (in addition to a loss of surface gloss,
such signs include chalking or flaking).
Always replace a hard hat if it sustains an impact,
even if damage is not noticeable. Hard hats also
should be replaced if dropped accidentally by the
worker from the height of a two story building or
higher. Damage to the hat and suspension from
the drop could seriously degrade the effectiveness
of the product.
Suspension systems are offered as replacement
parts and should be replaced when damaged or
when excessive wear is noticed (about every 12
months). It is not necessary to replace the entire
hard hat when deterioration or tears of the sus-
pension systems are noticed.
Do not mix suspension and helmet sizes. Make
sure the sizes match (standard size suspension
with standard-size helmet). For example, use only
Mine Safety Appliances Company (MSA) suspen-
sions on an MSA helmet. Failure to comply with
the above will reduce the energy-absorbing ability
of the protective helmet, which can result in se-
rious injury or death.
Frequently asked questions
Q: Can employees put stickers on hard hats?
A: OSHA regulations do not address the
“sticker” issue.
ANSI standard Z89.1-1997 does not specifically
address the issue either. It does advise workers to
take caution when marking or decorating Class
G (general) or Class E (electrical) helmets. The
ANSI standard warns against affixing markers
that would make holes or damage the hat.
A few stickers may be OK, but a hat full of them
could hide potential damage to the helmet. In
3
the end, it is up to the employer to decide if the
helmet is safe for the employee to wear.
Q: Is it OK to wear a hard hat backwards?
A: OSHA will ask: “Does wearing the hard hat
backwards meet the requirements of ANSI Z89.1
– 1969 — Safety Requirements for Industrial
Head Protection?” In other words, has the manu-
facturer tested the hard hat with the headband
backwards? If not, then it is not being worn
properly and OSHA could write a citation.
This issue is addressed in an OSHA letter of in-
terpretation, “The use of head protection at con-
struction sites,” dated July 22, 1992. “ANSI only
tests and certifies hard hats to be worn with the
bill forward; hard hats worn with the bill to the
rear would not be considered reliable protection
and would not meet the requirements of 29 CFR
1926.100 and unless the hard hat manufacturer
certifies that this practice meets the ANSI Z89.1
– 1969 requirements.”
Some manufacturers have come up with prod-
ucts with design features that meet their clients’
reverse donning needs. MSA offers a Swing-
Ratchet Suspension. Helmets equipped with the
Swing-Ratchet Suspension are third-party certi-
fied by the Safety Equipment Institute (SEI) in
both standard and reverse positions and meet all
applicable requirements of ANSI Z89.1-2003 for
Type I helmets. The 360-degree brimmed hard
hat is also gaining popularity.
Q: Is there a lifespan for hard hats?
A: Hard hats must be replaced when they can no
longer provide the protection intended, and
sometimes this can be difficult to detect.
OSHA does not specify the service life of a hard
hat, and there is no standard expiration time
frame for hard hats. The hard hat manufacturer
can recommend a replacement guideline for its
products, but hard hat life span may vary
significantly based upon the conditions at each
work site. Ultimately, an employer is responsible
for defining a responsive and appropriate
solution for hard hat service life issues.
Determining a specific time frame for hard hat
replacement at your site will take some research.
As a general guideline, most manufacturers
recommend replacing hard hats every five years
regardless of outward appearance. If work
conditions include exposure to higher
temperature extremes, sunlight, or chemicals,
hard hats should be replaced after two years of
use.
Vermont Local Roads suggests replacing your
helmet every 2-5 years. If your helmet is exposed
to the elements, including sunlight, it should be
replaced sooner. Refer to the Inspection and
Maintenance and When to Replace Hard Hats
requirements on page two for more details.
History of the hard hat
Established in San Francisco in 1898, Bullard
sold carbide lamps and mining equipment to
gold and copper miners. “The miners used to
wear a soft derby, similar to a baseball cap. It had
a small, hard-leather and
shellac brim,” said Edward
D. “Jed” Bullard, the
company’s fourth-
generation president
and chief executive
officer.
“In 1915, my grandfather began work on a hel-
met that could protect miners from falling ob-
jects. He based it on the doughboy, a helmet he’d
worn as a soldier in World War I. The ‘Hard-
Boiled Hat’, patented in 1919, was so called be-
cause of the steam used in the manufacturing
process,” said Bullard.
“The original ‘Hard-Boiled Hat’ was manufac-
tured out of steamed canvas, glue and black paint.
My grandfather built a suspension device into
what became the world’s first, commercially-
available, industrial head-protection device.”
First Designated “Hard Hat Area”
America’s first designated “Hard Hat Area” was
set up at the San Francisco Golden Gate Bridge
construction site. “The project’s chief engineer,
Joseph B. Strauss, shared a vision with my grand-
father that the workplace could be a safer envi-
ronment for the worker. One problem the bridge
project faced was falling rivets, which could cause
serious injury,” said Bullard. “My grandfather
transformed the mining helmet into a durable
industrial hard hat.”
Resources
Bullard, “From the Hard-Boiled Hat - Today’s
Skull Bucket: A History of Hard Hats.”
www.bullard.com/V3/products/head_
face/head_protection/Hard_Hat_History/
Lloyd, Michael. “Wearing a Hard Hat is Only
Half the Job”, Occupational Health and Safety,
March 2007, November 18, 2008.
www.ohsonline.com/Articles/2007/03/
Wearing-a-Hard-Hat-is-Only-Half-the-Job.aspx
Occupational Safety & Health Administration
osha.gov/pls/oshaweb/owadisp.show_docume
nt?p_table=STANDARDS&p_id=10663
MSA. “Understanding Changes to ANSI Stan-
dards – Z87.1, Z89.1, and Z117.1”.
http://media.msanet.com/NA/USA/HeadEye
Face/VGardProtectiveHelmets/VGardProtecti
veCapsandHats/5555-192ANSI_Changes.pdf
Stromme, Mark H. “Don’t be hard-headed”,
Industrial Safety & Hygiene News, June 1,
2008 BNP Media, November 18, 2008.
www.ishn.com/Articles/Feature_Article/BNP_
GUID_9-5-2006_A_10000000000000349307
www.tuffrhino.com/articles.asp?Id=128