Hard Hat Safety
The Problem
Head injuries can be life-altering—even fatal. On work sites, workers face risks from falling objects, electrical hazards, or bumping into fixed objects. Safety helmets (hard hats) are your first line of defence. However, improper use, poor maintenance, or failing to replace damaged helmets compromises protection. Today, we’ll discuss how to correctly wear, maintain, and replace helmets in line with WorkSafe New Zealand guidance to ensure your head stays protected.
Identify the Hazards
- Not wearing helmets in designated areas.
- Damaged or expired helmets may not offer proper protection.
- Wearing helmets incorrectly (e.g. backwards or with incorrect suspension).
- Modifications such as drilling holes or using unauthorised stickers.
- Poor storage leading to UV damage, heat exposure, or chemical deterioration.
Safety Practices and Preventative Measures
1. Helmet Types and When to Wear Them
Wear safety helmets in areas where there is risk of:
- Falling or flying objects.
- Striking fixed objects (e.g. pipes or beams).
- Electrical hazards (use electrically rated helmets).
Types of Helmets (AS/NZS 1801:1997):
- Type 1: General industrial use, resistant to impact and penetration.
- Type 2: Offers limited resistance to electrical hazards (not suitable for high voltage).
- Type 3: Bushfire fighting use (not typically for construction).
2. Inspection and Maintenance
Daily Checks:
- Look for cracks, dents, fading, or brittle plastic.
- Check the internal harness for fraying, broken clips, or stretching.
- Watch for signs of UV exposure (chalky finish or discolouration).
Cleaning:
- Wash using mild soap and warm water only.
- Avoid solvents or harsh chemicals.
- Air-dry out of direct sunlight.
3. Correct Use
Fit and Wear:
- Maintain clear space between the shell and your head for shock absorption.
- Wear the helmet forwards unless designed and approved for reverse wear.
- Secure chinstraps when working at height or in windy conditions.
No Modifications:
- Do not drill, cut, paint, or affix unauthorised stickers.
- Do not alter the harness or shell.
4. When to Replace
- Immediately after any impact—even if there’s no visible damage.
- Harness: Replace every 12 months.
- Shell: Replace every 3–5 years depending on exposure to sun and site conditions.
- Look for signs like cracking, fading, or brittleness.
5. Storage
- Store in a dry, cool place away from sunlight and chemicals.
- Do not leave in hot vehicles or exposed on dashboards.
Real-Life Case or Scenario
A construction worker was struck by a falling spanner from 6 metres above. He was wearing an AS/NZS 1801-compliant helmet, which absorbed the impact and prevented a serious injury. However, if he hadn’t inspected the helmet for damage before the shift, the result could have been much worse. Daily inspections save lives.
Employee Responsibilities
- Always wear your helmet in required areas.
- Inspect helmets before every shift.
- Report and replace damaged or expired helmets.
- Do not alter, modify, or misuse helmets.
Employer Responsibilities
- Supply compliant helmets to AS/NZS 1801:1997 standard.
- Replace helmets and harnesses as required.
- Provide training on care, inspection, and correct use.
- Keep records of inspections and replacements.
Discussion & Questions
- "Have you ever seen a helmet prevent a serious injury?"
- "What signs do you look for to know your helmet needs replacing?"
- "Do you feel confident inspecting and using your helmet properly?"
Allow time for employees to share feedback and raise concerns.
Commitment/Action Plan
Let’s commit to checking our helmets daily and reporting damage immediately. Take a moment before your shift today—inspect your helmet, check the harness, and make sure it's ready to protect you.
Wrap-Up
Your helmet protects your most important tool—your head. Proper use, regular inspection, and timely replacement make all the difference. Thanks for prioritising head protection and staying safe on-site.
Standards Overview
Under the Health and Safety at Work Act 2015 (HSWA) and WorkSafe NZ guidelines:
- Helmets must comply with AS/NZS 1801:1997.
- Employers must ensure head protection is provided and maintained.
- Workers must use PPE correctly and report any defects.
Disclaimer
These toolbox talks are provided for informational and educational purposes only and are not a substitute for professional legal, health and safety, or regulatory advice.
The content reflects recognised best practices and general industry standards as at the date of publication. However, it may not be applicable to all workplace environments or specific operational contexts.
It is the responsibility of the Person Conducting a Business or Undertaking (PCBU), as well as officers, workers, and other duty holders under the Health and Safety at Work Act 2015 (HSWA), to ensure compliance with all relevant laws, regulations, and WorkSafe New Zealand guidance.
The authors, presenters, and distributors of this toolbox talk disclaim all liability for any loss, damage, or injury arising from the use or reliance on the information provided. Users should seek advice from a suitably qualified health and safety professional or legal advisor for guidance tailored to their specific circumstances.
Always follow your organisation’s policies, procedures, and safe work practices to manage risks and maintain a safe and healthy workplace.
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