Not all hard hats are the same
A hard hat protects against two different things — impact and electrical contact — and the level of each protection varies by hard hat. Grabbing "a hard hat" off the shelf without checking the class or condition can leave a worker with less protection than they think they have.
Know your class
Class E hard hats protect against contact with up to 20,000 volts. Class G protects to 2,200 volts. Class C provides no electrical protection at all — some Class C hats have ventilation holes for comfort that also remove electrical protection. If there's any electrical hazard on site, Class E is the right call.
Check the shell before every shift
Look for cracks, dents, and deformation — even hairline cracks compromise the shell. Check for brittleness, chalking, or faded color, which are signs of UV damage that weaken the material. Any hard hat that shows these signs comes out of service immediately, no exceptions for "it still looks mostly fine."
The suspension matters as much as the shell
The suspension — the harness inside the hat — is what actually absorbs impact energy and keeps the shell off your head. A cracked, frayed, or loose suspension means the hard hat can't do its job even if the outside looks perfect. Replace suspensions on their own schedule — most manufacturers recommend every 12 months.
After an impact, replace it — even if it looks fine
If a hard hat takes a real hit — something falls and strikes it, or a worker bumps their head hard against something — that hard hat gets replaced. The impact energy may have been absorbed internally without leaving a visible mark, and the next impact could go straight through.
Discussion question
What class hard hat is everyone on this crew wearing today, and does it match the hazards — including electrical — present at this work site?
Documentation
Record this meeting: date, topic ("Hard Hat Safety"), attendee names, and facilitator. Documented training records — including toolbox talks — can be relevant in OSHA penalty proceedings, as evidence of an active safety program.