Wearing a well-worn hardhat is almost a freak flag for some. Stickers, logos, American flags, photos of the kids… the décor can stretch the gamut. No doubt, a hardhat is one of the most-recognizable pieces of safety equipment on the construction jobsite.

Yet it also is one of the most important pieces of safety equipment on the job. It protects your brain. Unfortunately, this ever-present piece of personal protective equipment (PPE) is rarely part of an inspection, maintenance or replacement program.

Many workers may be wearing a hardhat well past its useful life without even knowing it. The durable exterior of the rugged-looking hardhat can disguise the need for replacement. A hardhat is designed to protect you - only once.

If the hardhat has been struck by a forcible blow of any magnitude, both the hardhat shell and the suspension should be replaced immediately - even if no damage is visible.

Hardhats 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 its effectiveness. OSHA, ironically, does not specify the service life of a hardhat, and there is no standard expiration time frame for hardhats.

The hardhat manufacturer can recommend a replacement guideline for its products, but hardhat life span may vary significantly - based upon the conditions at each work site. As a general guideline, most manufacturers recommend replacing hardhats every five years - regardless of outward appearance.

If work conditions include exposure to higher temperature extremes, sunlight or chemicals, hardhats should be replaced after two years of use. Some manufacturers recommend the replacement of the hardhat 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 work conditions. The typical ANSI Type I-compliant hardhat, which provides protection from objects striking the top of the head, consists of two components: Shell and suspension. It is important that both shell and suspension are regularly inspected. 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 or dull in color or if it exhibits a chalky appearance. A hardhat should be replaced at first sign of any of these conditions.

To determine possible degradation of polyethylene shells, compress the shell inward from the sides about 1 inch (2.5 cm) with both hands and release the pressure without dropping the shell. The shell should quickly return to its original shape, exhibiting elasticity.

Compare the elasticity of the sample with that of a new shell. If the sample does not exhibit elasticity similar to that of a new shell or if it cracks due to brittleness, it should be replaced immediately.

(From the St. Louis Labor Tribune)