Do Hard Hats Expire? Shell Dates, Suspensions and Replacement

Bullard replacement suspension  · 

Is There an Expiry Date on a Hard Hat?

No printed expiry date exists, and the standard does not set one. ANSI/ISEA Z89.1, the US industrial head protection standard, and the European EN 397 contain no replacement timeline, so the limit comes from the manufacturer’s instructions for your model. OSHA’s rules at 29 CFR 1926.100 for construction and 1910.135 for general industry require head protection where there is a danger of falling objects, impact or electrical contact. They do not name a retirement age either.

What manufacturers do publish is a service life for each part, and the figures differ by brand and material. The shell, which is molded thermoplastic or fiberglass, is usually given a longer life than the suspension, the harness inside it. The U.S. Forest Service hardhat guide uses five years and ten years since the shell’s date of manufacture as decision points for closer inspection and retirement. Treat any one number as a starting point and check the sheet that came with your hat.

How to Read a Shell Date Code

The date code is molded into the shell, usually on the underside of the brim or inside the crown. Bullard’s date-code bulletin states that it shows when the hat was molded, not when it was bought or first worn. A hat that sat in a stockroom for two years has already used up part of its shelf age.

Many makers use a small clock-style dial. An arrow points at a number from 1 to 12 for the month, and the digits in the center give the last two digits of the year. Others mold the month and year as plain numbers, and Bullard’s codes also carry the day. If you cannot find the key for your brand, look it up in the maker’s care booklet rather than guessing.

The label inside the shell is the second thing to check. It lists the manufacturer, the ANSI designation, the type and the class. Type I covers impact to the top of the head, and Type II adds lateral impact. Class G is tested at 2,200 volts, Class E at 20,000 volts, and Class C offers no electrical protection. If that label has worn away, you cannot confirm the hat suits electrical work, and it should not be used for it.

Why the Suspension Wears Out Before the Shell

The suspension is the cradle of straps and the ratchet or pin-lock headband that holds the shell away from your skull. Its job is to spread an impact over time and keep a gap between the shell and your head. Sweat, sunscreen, heat cycling and constant flexing break down the straps and loosen the adjustment, so it fails sooner than the shell.

Some manufacturers set the suspension interval at no more than 12 months for certain helmets, and MSA is one of them. Bullard’s safety-helmet booklet recommends replacing the wearing parts, meaning crown pad liner, ratchet cover, brow pads and chin strap, every 12 to 18 months or sooner as needed. Heavy daily use in hot conditions justifies the short end of those ranges. Replace a suspension sooner if you find frayed or cut straps, cracks or tears, a ratchet that slips, or a headband that has gone stiff.

A suspension is not universal. Bullard lists its Bullard replacement suspension options by shell family, for example Classic models C30, C33, C34 and C35, and a ratchet hard hat suspension for one family does not necessarily fit another. An MSA V-Gard full brim hat is listed with a Fas-Trac III ratchet suspension, so the matching part is an MSA V-Gard Fas-Trac III suspension, but confirm the part against your exact shell in the maker’s parts list before buying.

Get Bullard replacement suspension Get MSA V-Gard Fas-Trac III suspension

Damage That Retires a Hard Hat Immediately

Daily inspection takes about thirty seconds. Look over the whole shell for cracks, dents, gouges, holes and tears, and for any area that has faded, turned chalky or gone brittle. Turn it over and check the suspension for cut or frayed straps, cracks around the ratchet, and rivets or clips that no longer seat in the shell slots.

A gentle squeeze of the shell sides, or a flex of the brim, will show crazing, which looks like a web of fine lines, or a crack opening up. Any crack, penetration or deep gouge ends the hat’s service. A scratch that only marks the paint is different from a groove that takes material away.

A hard blow is the other immediate trigger. Bullard instructs that if a forcible blow of any magnitude has struck the hat, the shell and suspension should be replaced immediately even if no damage is visible. The shell is designed to absorb energy once, by deforming, and a hat that has done that may look fine and protect poorly next time.

Heat, Sunlight, Chemicals and Modifications

A hard hat can degrade without any impact. Ultraviolet light and heat weaken thermoplastic shells over time, which is why a hat left on a truck dashboard in summer ages faster than one hung in a locker. Fading or a rough, chalky surface is the warning sign, and a brittle shell will crack instead of flexing.

Solvents are a quieter risk. MSA’s care guidance warns against paint thinner, solvents and hydrocarbon cleaners such as methyl ethyl ketone, and Bullard’s assembly instructions list paints, solvents, chemicals, adhesives and gasoline as substances that can destroy impact resistance without any visible sign. Clean the shell with mild soap and warm water, as MSA’s data sheet advises. Do not use detergents or harsh cleaners.

Do not drill, cut or engrave the shell. Bullard’s Classic C34 FAQ warns that engraving or modifying the shell in the crown area, or near the suspension key sockets, may stop it providing protection. Before putting stickers or markers on a hat, check the manufacturer’s list of approved products, since adhesives and the solvents in some marker inks are on the cautionary lists.

Replacing the Suspension or Buying a New Hat

Choose by what is worn out. If the shell is inside its service life and undamaged, and only the straps, headband or sweatband are tired, a replacement suspension costs far less than a new hat and restores the fit. Match it by brand, shell family and suspension type, such as 4-point or 6-point and ratchet or pin-lock, using the maker’s parts list for your model.

Buy a whole new hat when the shell has any crack or gouge, has taken a hard blow, shows faded or chalky plastic, is older than the maker’s stated life, or has lost its label so you cannot confirm type and class. If the hat was last on a site that now requires a different rating, for instance Class E for electrical work, a new hat is the only fix.

Write the date you installed a new suspension in marker on the inside of the shell only if the maker permits it. Otherwise keep a note in your gear log. Retire a hat by cutting through the suspension and shell so nobody picks it up from a bin.

FAQ

Do hard hats have an expiration date?

No law or standard sets one. ANSI/ISEA Z89.1 has no replacement timeline, so the limits come from the maker’s instructions for your model. Read the molded date code to find the manufacture date and compare it with the maker’s stated service life for the shell and suspension.

How often should a hard hat suspension be replaced?

Follow the maker’s sheet for your hat. Some set no more than 12 months for certain helmets, and Bullard recommends replacing wearing parts like the crown pad, brow pads and chin strap every 12 to 18 months or sooner. Replace it at once if straps fray, crack, or the ratchet slips.

Can I keep wearing a hard hat that was dropped or hit?

Not if it took a forcible blow. Bullard says to replace the shell and suspension immediately after one, even with no visible damage, because the shell absorbs impact by deforming. A hat that was only set down or knocked lightly can stay in service once it passes inspection.

Is it safe to put stickers or paint on my hard hat?

Only with the maker’s approval. Bullard lists paints, solvents, adhesives and gasoline as substances that can destroy a hat’s impact resistance without visible signs. Check the maker’s list of approved markings first, and never drill or engrave the shell.