Hard hat types, classifications, and uses: a pro's guide
From impact and electrical shock protection to role identification on the jobsite, hard hats prevent serious injury and save lives. The Occupational Safety and Health Administration (OSHA) and American National Standards Institute (ANSI) provide regulations and guidelines that outline hard hat requirements. These include hard hat types and classifications. In this article, we’ll cover:
OSHA and ANSI hard hat regulations
Types of hard hats
Hard hat classifications
Hard hats for plumbing and HVAC technicians
What are the OSHA and ANSI hard hat regulations?
OSHA 1910.135 Head Protection requires employees to wear hard hats when in areas with potential hazards, like falling objects or electrical shock. Review the entirety of OSHA 1910.135 here.
OSHA 1910.135(a)(1): The employer shall ensure that each affected employee wears a protective helmet when working in areas where there is a potential for injury to the head from falling objects.
OSHA 1910.135(a)(2): The employer shall ensure that a protective helmet designed to reduce electrical shock hazard is worn by each such affected employee when near exposed electrical conductors which could contact the head.
Although OSHA requires head protection, it does not detail the acceptable types or classifications. Rather, OSHA 1910.135(b) states head protection must comply with ANSI Z89.1 standards. The latest American National Standard for Industrial Head Protection version is ANSI/ISEA Z89.1-2014 (R2019). It covers types, classifications, testing and performance among other key safety recommendations.
Hard hat types
ANSI groups hard hats into two types: Type I and Type II. When selecting the safest hard hat for your worksite, first consider the Type. Then, select the appropriate hard hat Classification (General, Electrical or Conductive) - more on hard hat Classes below.
| Type I Hard Hats | Type II Hard Hats | |
|---|---|---|
| Impact Protection | Top of head | Top and sides of head |
| Example Hazards | Falling objects, Overhead hazards | Falling objects, Lateral impacts - from trips/falls, projectiles, collisions in confined spaces |
| Chinstrap | Optional | Optional - recommended when working at height or on uneven/slippery ground |
| Comfort | Typically lighter and more breathable | Extra helmet thickness generally increases weight and lowers breathability |
| Cost | $ | $$ |
Type I hard hats
Use Type I hard hats to protect workers from top-down impacts, for example, a falling object. When certifying Type I hard hats, ANSI also considers specific performance data, including flammability, force transmission, apex penetration and electrical classification. That’s why, in order to maximize safety, it’s important to shop for ANSI-approved hard hats.
Best-selling Type I hard hats
Type II hard hats
In comparison to Type I, Type II hard hats provide additional protection. Strategically placed suspension and extra thickness absorb both top-down and lateral/side impacts. This means Type II hard hats protect the front, back, sides and top of the head. Consequently, Type II hard hats are often the choice when you are working:
Near machinery that could cause unexpected lateral projectiles.
On uneven or slippery surfaces because it presents an increased tripping hazard.
At height due to the risk of falling and the likelihood of falling objects.
At a busy jobsite, which is unpredictable.
Best-selling Type II hard hats
Hard hat classifications
In addition to selecting between Type I and Type II hard hats, you need to determine which Classification of hard hats best suits your needs. ANSI standards outline three Classes: G (general hard hats), E (electrical hard hats) and C (conductive hard hats).
| Class G Hard Hats | Class E Hard Hats | Class C Hard Hats | |
|---|---|---|---|
| Electrical Shock Protection | 2,200 Volts | 20,000 Volts | NONE |
| Features | Optional chin strap | Optional chin strap | Optional chin strap, Lightweight, Ventilation |
| Typical Use | General construction, Manufacturing, Warehouse, HVAC/R, Plumbing, Iron workers | High-voltage utility, Power generation, Industrial sites, Electrical work | Welding, Job sites without electrical, Low-risk maintenance work, HVAC/R, Plumbing |
Classification G hard hats
Class G hard hats are the most commonly purchased style. They meet baseline ANSI standards for impact and penetration. In addition, they protect against electrical currents up to 2,200V.
Best-selling Class G Hard Hats
Class E hard hats
Use Class E hard hats when exposure to high voltage conductors is possible. They handle up to 20,000V (phase to ground). Please note that the dielectric protection is designated for the head only.
Best-selling Class E Hard Hats
Class C hard hats
Lightweight and often ventilated, Class C hard hats offer both comfort and protection. However, DO NOT use Class C hard hats around electrical current; they do not protect against electrical shock.
Best-selling Class C Hard Hats
Pro tip: Once you select the correct hard hat type and class, it’s important to consider comfort. The more comfortable your PPE is, the more likely you are to wear it properly. Take into account hard hat accessories such as sun visors, brim styles, hearing protection compatibility, chin strap attachments, overall fit and material. A comfortable, properly fitting hard hat can make all the difference during a long shift, not to mention that it reduces distraction and irritability.
Hard hats for HVAC/R and plumbing
HVAC/R and plumbing professionals often find themselves working on all sorts of jobsites. From residential calls to commercial projects and industrial facilities, it is important to have the proper personal protective equipment (PPE), including head protection. Having a few different hard hats in your work vehicle is a good idea.
Pro tip: Build a safety culture among your employees. Too often, serious injuries are caused because workers fail to put on PPE or take it off too soon. Offering high-quality, comfortable protection can help.
Hard hats in HVAC/R
From the roof to the crawl space, HVAC/R technicians face numerous and diverse hazards on the job. That’s why Type II hard hats are recommended. They protect the head from both top-down and lateral blows, like those you might get crawling around in cramped spaces with low beams and hard-to-see ceiling hangers. Furthermore, attaching the optional chin strap provides extra protection if you fall while walking on slippery or uneven surfaces, or if you knock your head while transporting heavy equipment into a mechanical room.
Most HVAC/R technicians keep two hard hat classes on hand: Type II, Class G and Type II, Class C. They use Class G hard hats when working with voltage, and Class C hard hats when there is no chance of electrical shock.
Hard hats in plumbing
Similar to HVAC/R technicians, plumbers work around various hazards at different job sites. Generally, a Type I, Class C hard hat is a safe option that provides both protection from falling tools and superior ventilation/comfort. However, when working with pressurized systems, it’s important to have a Type II hard hat on hand to protect against pressurized projectiles. Furthermore, when working near electrical hazards, a Class G or E hard hat may be required.
Pro tip: Many construction sites and buildings (including government buildings) have their own safety protocols. Keep this in mind when showing up to a new job and discuss the required PPE beforehand. This will ensure your crew has the safety gear they need to get the work done without incident.
Common hard hat colors and what they might mean
| Hard Hat Color | Commonly Worn By |
|---|---|
| White hard hats | Supervisors, Management |
| Green hard hats | Safety personnel |
| Blue hard hats | Engineers, Electricians, Technical expert |
| Red hard hats | Emergency personnel, First aid responders |
| Yellow hard hats | Laborers, Construction workers, Operators |
| Orange hard hats | Traffic control, Road workers |
| Brown hard hats | Welders, High-heat professionals |
Hard hat FAQs
When do I need to replace my hard hat?
Replace your hard hat after every incident. Otherwise, inspect the head protection gear regularly. Change the suspension straps every 12 months. If the hard hat is regularly exposed to chemicals or the sun, or is stored in a non-temperature-regulated space (such as a vehicle), retire it after 2 years. Otherwise, replace every 5 years unless you detect degradation (cracks, warping, chipping, etc.)
What are the Types of hard hats?
ANSI guidelines specify Type I and Type II hard hats. Type I hard hats offer protection when an object falls onto your head. Type II hard hats offer additional safety with both top-down and lateral impact/penetration protection.
What does the color of your hard hat mean?
Hard hat colors sometimes indicate specific roles on a job site. For example, supervisors and engineers often wear white hard hats, while laborers and operators wear yellow. That being said, color-coded hard hats are not universal. Check with the site’s safety personnel before making any assumptions.
Will I get a write-up for wearing my hard hat backwards?
If your hard hat has a reverse donning arrow, it may be safe to wear it backwards. Check the manufacturer's guidelines and discuss it with your team’s safety leader.
Is it okay to paint my hard hat?
No. ANSI guidelines advise against painting hard hats, as it may cause degradation due to the paint’s chemicals. For more information, reference ANSI Z89.1-2003, Appendix A4.
Can I add stickers to my hard yet?
Stickers or decals do not impact the integrity of your hard hat; however, check with company rules prior to adorning them.
Do hard hats cause hair loss?
No. Hard hats do not cause hair loss. They can, however, prevent serious head injuries.
Put safety first with Ferguson
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