Hard hats are an essential piece of personal protective equipment (PPE) for many workers. They help protect the head from impact, penetration, and electrical shock. But do hard hats expire and need replacing? Let’s take a look at what OSHA and other safety organizations say about replacing hard hats.
OSHA requirements for hard hat expiration
OSHA does not have a specific regulation stating when hard hats expire and must be replaced. However, OSHA does require that personal protective equipment – including hard hats – be maintained in a safe, sanitary condition and ready for use (29 CFR 1910.132(e)).
So while OSHA does not mandate replacing hard hats after a certain amount of time, they do require that hard hats be inspected regularly and replaced if they are no longer in good condition. The key factors in determining if a hard hat needs replacement are:
- Damage – Major dents, cracks, penetrations or other physical damage compromise the integrity and protective ability of the hard hat. Damaged hard hats should be replaced immediately.
- Wear – Normal wear from use that degrades the materials over time. This includes fading, chalking and loss of gloss on the shell.
- Contamination – Dirt, chemicals, paint and other contaminants can degrade materials over time. Hard hats should be cleaned regularly.
- Age – While aging alone does not damage a hard hat, the recommended service life provides guidance on when to replace.
So OSHA does not provide an exact expiration date, but requires hard hats be properly maintained, inspected and replaced as needed to provide continued protection.
Manufacturer expiration recommendations
Since OSHA does not provide a specific hard hat expiration date, following manufacturer recommendations is best practice. Most major manufacturers recommend replacing hard hats at least every 2-5 years under normal use conditions. Here are the service life recommendations from leading manufacturers:
| Manufacturer | Recommended Replacement Schedule |
|---|---|
| MSA | 5 years from date of manufacture |
| Bullard | 5 years from first use |
| Pyramex | 5 years from date of manufacture |
| 3M | 3-5 years from first use |
| Honeywell | 5 years from first use |
As you can see, most manufacturers recommend replacing hard hats every 3-5 years. This accounts for normal material degradation from UV exposure, temperature fluctuations, contaminants and normal wear and tear.
However, the service life can be shorter or longer depending on use conditions. Extreme temperatures, exposure to chemicals/sunlight, frequent impacts and improper storage decrease service life. Minimal use and proper care extend service life. Periodic inspection and following manufacturer instructions is key.
Indicators a hard hat needs replaced
In addition to age and manufacturer recommendations, there are visible signs that indicate a hard hat should be taken out of service and replaced. Make sure to routinely inspect hard hats for any of these indicators that lifespan has been exceeded:
- Cracks or perforations in the shell, harness or suspension – Any visible cracks or holes indicate the integrity is compromised.
- Flaking/chalking of the shell surface – This breakdown indicates material degradation.
- Fading/discoloration – Fading and loss of gloss shows the effects of UV exposure.
- Warping/distortion of the shell or suspension – Indicates heat or impact damage.
- Worn sizing components – Inability to adjust and securely fit the hard hat indicates replacement needed.
- Deformation from an impact – Even invisible damage can reduce future protection.
Any of these signs of wear and reduced integrity means a hard hat should be taken out of service and replaced. Don’t take changes with compromised PPE – inspect regularly and follow manufacturer instructions.
Recommended hard hat replacement schedule
Based on OSHA requirements, manufacturer recommendations and service life indicators, here are the best practices for hard hat replacement:
- Inspect hard hats before each use for damage or wear
- Clean and disinfect hard hats regularly according to manufacturer instructions
- Replace hard hats that show any signs of damage or wear
- Replace hard hats at least every 2-5 years from first use
- Replace hard hats earlier if exposed to heavy use, harsh conditions, chemicals, extreme temps
- Always follow specific manufacturer instructions
- Mark the issue date so age can be tracked
- Provide new hard hats as needed to maintain worker safety and compliance
While a specific expiration date isn’t mandated, following this replacement schedule helps ensure hard hats maintain their protective abilities. Training workers on inspection, care and replacement requirements is also critical. Provide the right PPE, training and policies to keep workers safe on the job.
Other frequently asked questions
Here are answers to some other common questions about hard hat expiration and replacement:
Do hard hats expire if not used?
Yes, the recommended replacement schedule applies whether or not the hard hat is used. Materials and components still degrade over time when exposed to aging and environmental factors.
How do you dispose of old hard hats?
Hard hats should be disposed of properly to prevent unauthorized re-use. Cutting the shell into pieces is recommended. Follow local waste and recycling regulations. Hard hats past service life should not be donated or resold.
Can old hard hats be reconditioned/repaired?
No, attempting to repair or recondition used hard hats is not recommended. The integrity of the materials cannot be restored. Damaged or worn hard hats should be replaced entirely with new units.
Does cold weather extend the life of hard hats?
Cold conditions may slightly extend service life by slowing material degradation. However, impacts and wear still occur with use. Follow manufacturer recommendations regardless of climate conditions.
When should hard hats be replaced after an impact?
Hard hats that sustain an impact should be immediately removed from service and replaced. Even if no external damage is visible, the impact protection may be significantly reduced.
Conclusion
While OSHA does not provide a hard and fast rule for replacing hard hats, following manufacturer recommendations, observing indicators of wear and setting proactive replacement schedules is important. A service life of 2-5 years under normal conditions provides reasonable assurance hard hats remain protective. But regular inspection and training is still vital. Workplace safety, production and liability all depend on workers having access to functional PPE in good condition. So provide the tools, resources and culture of safety to keep everyone protected on the job.
