MILLIONS of
hard hats are worn every day. In fact, the hard hat is one of the most
recognizable pieces of safety equipment in the industrial workplace. It's also
one of the most important pieces of safety equipment because it protects the
brain. Unfortunately, this ubiquitous piece of personal protective equipment
(PPE) is rarely part of an inspection, maintenance, or replacement program.
Many workers may be wearing a hard hat well past its useful life without
even knowing it.
The durable exterior of the rugged-looking hard hat can
disguise the need for replacement. Hard hats must be replaced when they can no
longer provide the protection intended, and sometimes this can be difficult to
detect. Workers who use gloves on a work site can obviously see (and feel) the
need for new gloves; the wear and tear is readily apparent. On the other hand,
many workers may be wearing a hard hat well past its useful life without even
knowing it. In every organization where workers wear head protection on the
job, a regular hard hat replacement program should be clearly defined and
implemented. This type of hard hat replacement program can be implemented and
managed with a few considerations.
OSHA, ironically, 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.
Useful Life of a Hard Hat
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. Some manufacturers recommend the replacement of the hard hat suspension
every 12 months, regardless of appearance. Careful review of each work site is
critical to ensure that degradation of PPE is not being accelerated due to
extreme
Inspection and Maintenance
The typical ANSI Type I-compliant hard hat, which
provides protection from objects striking the top of the head, 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.
Shell Inspection
Throughout history, many materials have been used to manufacture hard hat shells. Today, thermoplastics (polyethylene, polycarbonate, and others) and thermo set materials (fiberglass-reinforced polyesters and phenolic-impregnated textiles) are commonly used to mold shells of industrial hard hats. These materials have proven to be durable, reliable, and lightweight while providing effective protection. Given proper care, these materials will provide a reasonable service life under normal workplace conditions. But remember, these hard hats do not have an indefinite useful life, nor are they resistant to all physical and chemical exposures.
Throughout history, many materials have been used to manufacture hard hat shells. Today, thermoplastics (polyethylene, polycarbonate, and others) and thermo set materials (fiberglass-reinforced polyesters and phenolic-impregnated textiles) are commonly used to mold shells of industrial hard hats. These materials have proven to be durable, reliable, and lightweight while providing effective protection. Given proper care, these materials will provide a reasonable service life under normal workplace conditions. But remember, these hard hats do not have an indefinite useful life, nor are they resistant to all physical and chemical exposures.
Regardless of the material, shells should be inspected
routinely for dents, cracks, gouges, and any damage due to impact, penetration,
abrasions, rough treatments, or wear that might reduce the degree of protection
originally provided. Degradation of thermoplastic material may be apparent when
the shell becomes stiff, brittle, faded, dull in color, or exhibits a chalky
appearance. A hard hat should be replaced at first sign of any of these
conditions.
Careful review of each work site is critical to ensure that degradation of
PPE is not being accelerated due to extreme work conditions.
Exposure to direct sunlight will affect the
life of the shell
Although most manufacturers add an ultraviolet inhibitor
to the shell material of hard hats to protect against degradation caused by
sunlight, all hard hats are susceptible to ultraviolet light damage. Workers
should never store their hard hats in the rear window or dash of a vehicle or
in direct sunlight. This is the quickest way to degrade the shell material and
reduce the life of the product.
Suspension Inspection
The hard hat suspension is just as important to worker safety as the shell. The suspension actually helps to absorb the shock of a blow, so it must be in good condition at all times. Like the shell, the suspension must be inspected regularly and replaced from time to time. Suspensions should be inspected closely for cracks, frayed or cut crown straps, torn headband or size adjustment slots, loss of pliability, missing components, or other signs of wear. These conditions can be caused by perspiration, hair oils, or normal wear.
The hard hat suspension is just as important to worker safety as the shell. The suspension actually helps to absorb the shock of a blow, so it must be in good condition at all times. Like the shell, the suspension must be inspected regularly and replaced from time to time. Suspensions should be inspected closely for cracks, frayed or cut crown straps, torn headband or size adjustment slots, loss of pliability, missing components, or other signs of wear. These conditions can be caused by perspiration, hair oils, or normal wear.
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