Hard Hat Safety Toolbox Talk: Talking Points, Questions and Checklist

This hard hat safety toolbox talk is for crews working where tools or materials can fall, where there's low headroom, or near overhead electrical hazards. It takes about five minutes. Ask everyone to take off their hard hat and inspect it during the talk. The crew should leave knowing what a damaged hard hat looks like and when to swap it out.

Why does head protection matter?

A hard hat is designed to deflect falling objects and absorb the shock of a blow. It can only do that if it's in good condition and worn properly. In the US, OSHA 1910.135 requires protective helmets where there's a potential for head injury from falling objects. It requires helmets designed to reduce electrical shock where exposed conductors could contact the head.

Hard hats degrade over time. CCOHS explains that heat, sunlight and chemicals can make shells stiff or brittle, sometimes with a pattern of tiny cracks or a chalky look. It says to replace headwear that has been struck even if no damage is visible.

The space between the suspension and the shell is part of the protection. CCOHS notes this clearance helps absorb the shock of a blow, which is why nothing should be stuffed between the two. Standards and rules differ by country, so check the rules where you work.

Talking points for your hard hat safety toolbox talk

• Wear it where it's required. Hard hat areas are marked for a reason: overhead work, cranes, racking or low beams. Keep it on the whole time you're in the zone, not just when someone's watching.
• Inspect the shell before each use. Look for cracks, dents, gouges, a dull or chalky surface, and stiffness. If in doubt, take it out of service.
• Check the suspension too. Look for torn straps, broken stitching and cracked clips. A damaged suspension can't absorb an impact properly.
• Adjust it to fit. It should sit level and stay put when you bend over. Use the headband adjustment rather than a cap underneath.
• Don't modify it. No drilling, painting or cutting. Solvents in paint can make the shell brittle and hide cracks. Check with the manufacturer before adding stickers or accessories.
• Store it out of the sun. The rear window shelf of a vehicle is one of the worst places for a hard hat. Heat and UV light weaken the plastic.
• Replace it after a significant impact. Even if it looks fine, a hard hat that has taken a heavy blow may have hidden damage. Swap it and report what happened.

Example to share with the crew

For example, a site worker keeps their hard hat on the dashboard of their truck all summer. It looks fine from a distance, but up close the shell has faded and has fine cracks across the crown. When a small fixing falls from a scaffold above, the shell cracks right through instead of deflecting it.

The hard hat was being worn, just not looked after. Ask the crew where they keep theirs between shifts.

Hard hat safety checklist

• Hard hat areas clearly marked
• Shell free of cracks, dents, gouges, chalkiness and brittleness
• Suspension intact, with no torn straps or broken clips
• Hard hat adjusted to sit level and secure
• No paint, drilled holes or unapproved accessories
• Electrically rated hats used near exposed conductors
• Hats stored away from direct sunlight and heat
• Hats that have taken an impact removed from service

Questions to ask the crew

1. When did you last inspect your hard hat, shell and suspension?
2. Where do you keep your hard hat between shifts?
3. What would you do if something hit your hard hat but it looked undamaged?

How to close the talk

What this hard hat safety toolbox talk comes down to: inspect it, fit it, look after it, and replace it after an impact. If your hard hat is damaged, faded or has taken a hit, report it to your supervisor and get a replacement before you go back into a hard hat area. For more PPE discussions, see the eye and face protection talk or our full list of toolbox talk topics.