Hard Hat Inspection Guidelines

1. The shell should be inspected routinely for dents, cracks, nicks, gouges, and any damage due to impact, penetration, abrasions, rough treatment, or wear that might reduce the degree of protection originally provided. Any hard hat that shows signs of worn or damaged parts should be removed from service and replaced immediately.

All hard hats are susceptible to damage from ultraviolet light, temperature extremes, and chemical degradation. Therefore, those who work in environments with high degrees of exposure to sunlight, heat, cold, or chemicals should replace their hard hats more frequently than those working in other environments.

Degradation of thermoplastic materials may be apparent when the shell becomes stiff, brittle, faded, dull in color, or exhibits a chalky appearance. With further degradation the shell surface may craze, flake, or delaminate. A hard hat should be replaced immediately at the first sign of any of these conditions.

An approved, simple field test that should be performed by employees, supervisors, cache managers etc. to determine possible degradation of shells:

Compress the shell inward from the sides about 1" with both hands and then release the pressure without dropping the shell. The shell should return quickly to its original shape, exhibiting a degree of elasticity. Compare the elasticity of the sample with that of a new shell. If the sample does not exhibit a similar degree of elasticity to that of the new shell or if it cracks due to embrittlement, it should be replace immediately.

2. The suspension, as important as the shell, must also be inspected and replaced periodically. Suspensions should be inspected closely for cracks, frayed or cut shell straps, torn headband or size adjustment slots, loss of pliability, or other signs of wear. Any suspension that is damaged must be removed from service and replaced immediately.

Field personnel exposed to heavy hard hat usage and sunlight should check hardhats at least monthly, if not more frequently; others at least annually. Consideration should be given to rotating cache stock inventories into the workforce on a scheduled basis, so that new purchases may replace older stock. While no automatic replacement schedule is mandated, it is extremely important that inspections, necessary cleanings etc occur minimally on an annual basis, or more frequently with heavier usage and exposure.

For additional information, consult NFES 2249 "Fire Equipment Storage and Refurbishing Standards", which includes: USDA-Forest Service Tech Tip 9267-2323-MTDC "Maintaining and Inspecting Your Hardhat"; NWCG Memorandum "Protective Headgear " 6/28/93; ANSI Z89.1-1986 App. B "Recommendations and Precautions Concerning Helmet Use, Maintenance and Testing"; and E.D. Bullard Company's "Industrial Head Protection User Information Guide."