Hard hats, or helmets, are protective equipment required in the construction industry to prevent head injuries.

These helmets are made from high-density polyethylene (HDPE), a nonconductor of electricity. They also have foam lining and suspension systems made of vinyl, nylon, or molded HDPE.

This cushions workers against electric shocks and acts as a shock absorber. 

The History Of The Hard Hat

Shipbuilding industry workers wore the first documented hard hats. These industry workers would cover their hats with tar and cure them in the sun. The hats protected their heads from objects dropped into the ship decks.

Edward W. Bullard invented the first commercially available hard hat in 1919. Edward Bullard was a graduate of the University of California and the son of a mining equipment seller (Edward Dickinson Bullard).

Upon completing his university degree, he returned home to work in E.D Bullard Co., his father’s company, which sold mining equipment such as carbide lamps to gold and copper miners.

During this time, he noticed a need for protective headgear and created a prototype.

He made his first design inspired by the doughboy helmet he wore when he served in the army during WWI. Edward made the “hard-boiled hat” with steamed canvas, cork, and glue.

This model quickly became popular with miners and spread the safety culture to other industries as it protected workers from falling debris. The US Navy adopted the model for their deck workers that same year.

Edward Bullard would later make and patent several improvements to his original prototype, such as an adjustable suspension system to make his hat more effective.

The Evolution Of Hard Hats

Since the invention of the hard hat, several innovations in safety helmets have occurred over the years.

• 1930: Mine Safety Appliances (MSA) introduced Skullguard, a non-conductive thermoplastic hard hat for metal industry workers that could withstand temperatures up to 350 ℉.
• 1931: Six Companies mandated using construction safety helmets for the Hoover Dam project.
• 1933: Joseph Strauss asks Bullard to create safety helmets to protect the Golden Gate Bridge construction workers who performed sandblasting.
• The 1940s: Fiberglass shell helmets began to replace the traditional aluminum and steel hard hats.
• The 1950s: Thermoplastics began to replace fiberglass as the material of choice for hard hats due to its durability and cost-effectiveness.
• The 1960s: The Occupational Safety and Health Act (OSH act) was introduced, causing companies to pay more attention to safety protocols in the workplace and increasing the demand for hard hats.
• 1961: MSA developed the first polycarbonate hard hat, the Topguard helmet.
• 1962: The V-Guard helmet (the most common hard hat in the US) was introduced, with a patented shock-absorbing liner.
• 1977: ANSI gives the green light for developing ventilated safety helmets to keep workers cool.
• The 1980s: Bullard adds a nonslip ratchet system to their helmets, increasing the comfort and fit of the hard hats. The front brim was added to helmets to help shield workers from the sun.

The Latest Trends & Research

Advanced Technologies

Today, safety helmet accessories are more sophisticated and include advanced technologies such as augmented reality glasses, ear muffs, and air filtration systems.

Most recent advances in technology in safety helmets include smart hard hats with IoT devices.

These smart helmets are ideal for lone workers as they have sensors that relay information about a worker’s location and a microphone and camera for voice and video call capabilities.

Color Coding

Helmets also come in an assortment of colors. These color codes help to identify the user’s rank and help with workplace organization.

For instance, the color for road construction workers’ helmets is orange, while supervisors, foremen, and engineers wear white.

Safety Helmet Material

In 2021, the global safety helmet market was worth an estimated $3.9 billion.

Most construction safety helmets on the market are made from polyethylene as it is cheap and provides better head protection even against the shock of blows from falling objects.

Research

In terms of research, scientists are working on developing new materials that will be lighter yet more durable than current hard hats.

These materials include polyurethanes that are able to dissipate energy.

The Best Hard Hats On The Market

Head and brain injuries are among the most common injuries in the construction industry.

According to OSHA, construction workers must wear hard hats if there’s a risk of electrical shocks, objects falling from above, or other objects that workers may bump into.

There are five main types of hard hats on the market as classified by ANSI standards:

• Type 1 hard hats: They protect from top impact hazards.
• Type 2 hard hats: They protect both top and lateral impact hazards.
• Class G hard hats: These are the most common of all hard hats. They protect against impact and electrical shocks up to 2200 volts.
• Class E hard hats: Protect from electrical shock hazards while providing head protection.
• Class C hard hats: Protect against minor splashes and sprays of liquids and dust.

If you’re looking for the best hard hats on the market, here’s a list to help you out:

• The Milwaukee 6-Point Suspension Type 1 Full Brim Hard Hat is one of the lightest hard hats you’ll find on the market. It has a large ratchet range compared to other hats. This means that it can fit most head sizes. 
• The 3M H-700 series is lightweight yet durable and has a sweatband for added comfort. It also features a suspension system that self-adjusts to the wearer when the ratchet is tightened and has air ventilation channels.
• Klein Tools 60347 is a class C Type 1 hard hat that features a six-point suspension system for better comfort and a sweatband to absorb moisture. It also has a rain trough to help keep the wearer’s face dry in wet conditions.
• Pyramex Ridgeline XR7 is an ANSI Type 1 Class E-rated hard hat with a six-point ratchet suspension system and a removable, washable brow pad. It also has shock absorption and electrical insulation properties.
• Bullard Cen10 Type 1 Safety Helmet has a foam insert instead of a suspension system, making it lightweight and comfortable. It also features an adjustable ratchet-style headband and vents to keep the wearer cool. However, it doesn’t have a brim.

Conclusion

As hard hats technology continues to advance, it’s important for contractors to ensure that their workers are protected with the best safety helmets available. Familiarize yourself with the local occupational health and safety regulations so that you can remain compliant when it comes to hard hats in construction.

References

• https://www.invent.org/inductees/edward-bullard 
• https://www.contractcomplete.com/history-of-the-hard-hat/ 
• https://www.smithsonianmag.com/innovation/history-hard-hat-180974238/ 
• https://www.equipmentworld.com/workforce/safety/article/14970852/the-history-of-the-hard-hat-in-the-construction-industry 
• https://en.wikipedia.org/wiki/Brodie_helmet 
• https://www.workerslaw.com/posts/new-hard-hat-aims-to-protect-construction-workers-from-concussions/ 
• https://www.grandviewresearch.com/industry-analysis/safety-helmet-market 
• https://www.creativesafetysupply.com/articles/hardhat-classes/ 
• https://www.911metallurgist.com/blog/hard-hats 
• https://www.protoolreviews.com/coolest-and-most-comfortable-hard-hats/ 
• https://blogs.cdc.gov/niosh-science-blog/2022/11/10/construction-helmets 
• https://www.emcins.com/losscontrol/insights-d/2020/03/hard-hat/