PPE/Specific/TBT-PPE-006

Hard Hat Types and Standards

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Hard Hat Types and Standards

Toolbox Talk Record

Ref: TBT-PPE-006  |  Issue: 1  |  Date: March 2026
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What?

  • Hard hats protect against falling objects, head strikes, and electrical contact on site.
  • The current standard is EN 397 for industrial helmets and EN 12492 for mountaineering-style.
  • Vented helmets must not be used where there is a risk of liquid splash or molten metal.
  • Hard hats have a limited lifespan — most manufacturers recommend replacement every 3 to 5 years.
  • UV exposure, impact damage, and chemical contact all degrade the shell and reduce protection.
  • The chin strap must be worn correctly — an unsecured hard hat falls off on impact.
  • Some tasks require helmets with additional features such as face shields or ear defenders.
  • Hard hats must be correctly adjusted using the internal harness system for the wearer.
  • Stickers, paint, and solvents applied to hard hats can weaken the shell material.
  • The PPE at Work Regulations 2022 require employers to provide suitable head protection.

Why?

Prevent head injuriesHead injuries from falling objects cause death and brain damage on site.
Correct standardUsing the wrong type provides inadequate protection for the task.
Shell degradationExpired or damaged helmets fail on impact — replacement is essential.
Legal dutyPPE Regulations require employers to provide and maintain head protection.
Do Don't
  • Wear your hard hat at all times in designated hard hat areas on site.
  • Check the manufacturing date and replace helmets older than the stated lifespan.
  • Adjust the internal harness so the helmet fits securely on your head.
  • Fasten the chin strap to prevent the helmet falling off during work.
  • Inspect your helmet daily for cracks, dents, UV damage, or fading.
  • Select the correct helmet type — vented, full brim, or electrical rated.
  • Replace any hard hat that has sustained a significant impact immediately.
  • Store your helmet away from direct sunlight and chemicals when not in use.
  • Use compatible attachments from the same system for visors and defenders.
  • Report any defective or uncomfortable helmets and request a replacement.
  • DON'T wear a hard hat that is cracked, dented, or past its expiry date.
  • DON'T modify your helmet by drilling holes, painting, or applying solvents.
  • DON'T wear a baseball cap under your hard hat — it prevents proper fitting.
  • DON'T use a vented helmet where liquid splash or molten metal is a risk.
  • DON'T leave your hard hat on the dashboard — heat and UV damage the shell.
  • DON'T wear your hard hat backwards unless designed to be reversible.
  • DON'T remove the internal harness or cradle — it absorbs impact energy.
  • DON'T assume all hard hats provide the same level of protection.
  • DON'T throw or sit on your hard hat — this causes hidden damage.
  • DON'T share hard hats without adjusting the harness for the wearer.

See also: PPE Awareness and Responsibilities | Correct PPE for the Task
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