When must head protection be replaced?

OSHA’s general requirements for personal protective equipment at 1910.132(e) says that, “Defective or damaged personal protective equipment shall not be used.”

Hard hats with any of the following visible defects should be removed from service and replaced:

• Perforation, cracking, or deformity of the brim or shell; and
• Indication of exposure of the brim or shell to heat, chemicals, or ultraviolet light and other radiation (in addition to a loss of surface gloss, such signs include chalking or flaking).

OSHA says to always replace a hard hat if it sustains an impact, even if damage is not noticeable. Suspension systems are offered as replacement parts and should be replaced when damaged or when excessive wear is noticed. It is not necessary to replace the entire hard hat when there is deterioration or tears of the suspension system.

Be aware that replacement should not be based solely on visible defects or damage. OSHA says in the preamble to the April 1994 final rule:

“OSHA certainly agrees that visibly damaged or defective PPE must not be used. However, there are other methods (such as performance tests to ensure continued integrity) that the employer could use to assure that the PPE used by employees is repaired or replaced as necessary for the protection of each affected employee. Also, employees can often determine if the protectiveness of the PPE has been compromised when they are handling the PPE prior to or while donning it.”