Hard hats are a vital piece of personal protective equipment for many workers. They help protect the head from impact, penetration, and electrical shock. There are four main types of hard hats that provide protection in different environments and for different hazards. Knowing the key differences between hard hat types is critical for ensuring you select and use the appropriate hard hat for the job.
The 4 Main Hard Hat Types
The four main types of hard hats are:
| Type I hard hats | Type II hard hats |
| Type I class G hard hats | Type I class E hard hats |
Let’s look at each of these in more detail:
Type I Hard Hats
Type I hard hats are designed to reduce force from blows to the top of the head. They withstand impacts from falling objects but do not provide electrical protection. Type I hard hats are the most common general-purpose hard hat used in construction, maintenance, manufacturing, and other jobs where protection from falling or flying objects is needed.
Key features:
- Withstand blows from above
- Do not protect against electrical hazards
- Full brim provides additional protection from sun glare and falling objects
Type I hard hats are suitable for jobs like:
- Construction
- Mining
- Forestry
- Shipbuilding
- General labor
Type II Hard Hats
Type II hard hats provide high-voltage electrical protection in addition to impact protection. They are designed with dielectric properties that provide insulation against electrical currents. Type II hard hats meet ANSI standards for protecting against voltages up to 20,000 volts.
Key features:
- Withstand blows from above
- Provide protection from electrical hazards
- Do not have full brim like Type I
Type II hard hats are suitable for:
- Electric utility work
- High voltage electrical services
- Any environment with risk of exposure to electrical shock
Type I Class G Hard Hats
Type I Class G hard hats meet all the requirements of a Type I hard hat for impact protection. Additionally, they provide protection from falling objects and contact with low-voltage conductors up to 2,200 volts. This makes them a versatile option for general industry, utilities, and construction where electrical hazards may be present.
Key features:
- Withstand blows from above
- Provide protection from electrical hazards up to 2,200 volts
- Full brim for sun/impact protection
Type I Class G hard hats are suitable for:
- Construction sites with electrical systems
- Electrical contractors
- Factory maintenance personnel
- Any environment with risk of falling objects and low voltage exposure
Type I Class E Hard Hats
Type I Class E hard hats provide the highest level of protection from electrical hazards of any ANSI certified hard hat. They meet Type I impact standards and can withstand contact with conductors carrying up to 20,000 volts. This makes them ideal for high voltage electrical work.
Key features:
- Withstand blows from above
- Highest level electrical protection (up to 20,000 volts)
- Do not have full brim like Type I
Type I Class E hard hats are designed for:
- Electric power generation facilities
- High voltage power line work
- Substations and switchyards
- Any environment with extremely high voltage exposure
Hard Hat Components
While the materials and ratings differentiate hard hat types, all hard hats share common components. These include:
Shell – The rigid outer body that withstands and deflects blows. Made from materials like high density polyethylene (HDPE) or fiberglass.
Suspension – The harness inside the hat that cushions and absorbs shock. Typically has a headband and crown straps.
Brim – The extended visor that provides additional protection from sun glare and falling objects for some types.
Chin strap – A strap that secures the hard hat firmly on the head. Highly recommended for optimal safety.
Hard Hat Materials
Hard hats are constructed from strong, impact-resistant materials. The most common materials used are:
High Density Polyethylene (HDPE) – A lightweight, durable plastic used in most hard hat shells. Provides excellent impact protection.
Fiberglass – A composite material used for high heat applications up to 350°F. More expensive but very strong.
Aluminum – Used in some lightweight cap style hard hats. Not as impact resistant as HDPE or fiberglass.
Combination – Some feature a molded HDPE cap with a fiberglass peak for increased durability.
HDPE is suitable for most general work environments. Fiberglass is preferred for high heat applications like smelting or firefighting. Aluminum and combination hard hats offer lightweight options but less impact protection.
Hard Hat Ratings
All hard hats must meet safety standards for performance set by ANSI or CSA. Key ratings include:
Impact protection – Measured as the amount of force absorbed upon impact. Ranges from low 100 joules to high 440 joules.
Voltage protection – Rated as Class G (up to 2,200 volts), Class E (up to 20,000 volts), or no rating (no electrical protection).
High temperature resistance – Some rated for use in extreme heat up to 350°F.
Higher impact ratings, voltage protection, and heat resistance indicate better safety performance. Matching ratings to work environment hazards is critical.
Key Considerations When Selecting a Hard Hat
Choosing the right hard hat requires considering your work environment conditions and potential hazards. Key factors in selecting the appropriate hard hat include:
- Impact hazards – Match high impact rating to the force of potential falling objects.
- Electrical hazards – Select Class G or E protection as warranted.
- Heat exposure – Consider high heat rating for hot environments.
- Sun exposure – Opt for wide brim Type I for outdoor use.
- Task-specific needs – Certain jobs require specialized designs.
- Comfort and fit – Prioritize models with adjustable suspensions.
Consulting safety professionals and assessing all hazards in your workplace is recommended when choosing a suitable hard hat. Proper selection, care, and use are vital to maximize hard hat safety benefits.
Care and Maintenance of Hard Hats
To prolong the service life of hard hats and ensure they remain protective, proper care and maintenance are essential. Key practices include:
- Inspect regularly for cracks, dents, or deterioration.
- Replace suspension systems at least every 12 months.
- Discard and replace hard hats after any significant impact.
- Avoid painting or applying unauthorized stickers/decals.
- Clean regularly with mild soap and water.
- Store away from direct sunlight, heat, and chemicals when not in use.
Always follow the manufacturer’s instructions for use and care. Replace hard hats according to manufacturer’s specified expiration dates. Proper maintenance keeps hard hats in optimum working condition.
Importance of Proper Fit and Use
To provide effective protection, hard hats must fit correctly and users must wear them properly. Key guidelines include:
- Hard hat should be low on the head and tilted slightly forward.
- Adjust suspension size to get a snug, comfortable fit.
- Use added accessories like chin straps for very active work.
- Fasten any chin strap, goggles, or face shield securely.
- Take off hard hats by the shell, not the suspension.
- Never alter the shell shape or drill holes.
Workers should be trained on proper hard hat use as part of an overall head protection program. Always consult the manufacturer’s instructions as well. Correct fit and use is essential to realize the safety benefits of any hard hat.
Advantages of Wearing Hard Hats
While hard hats may feel cumbersome initially, the protective benefits far outweigh any minor inconvenience. Key advantages include:
- Absorbs force of blows to prevent traumatic head injuries
- Shields from falling and flying objects, debris, and materials
- Insulates from electrical currents and high voltages
- Protects from burns in high heat environments
- Cushions impact from fixed objects like beams or pipes
- Prevents injuries that cause death or permanent disability
Studies confirm that wearing hard hats significantly reduces the incidence, severity, and fatalities of head-related workplace injuries. Their use is mandated by OSHA and other regulations to protect workers from preventable harm.
Conclusion
Hard hats represent an essential piece of personal protective equipment that shields the head from multiple injury hazards. The four main types that serve unique functions include Type I, Type II, Class G, and Class E. Matching the appropriate hard hat style and ratings to work environment risks is critical. When worn and cared for properly, hard hats prevent traumatic brain injuries and save lives. Their use should be strongly encouraged and enforced as a basic safety practice in every industrial workplace.
