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Here's What Goes Into Making A Strong Hard Hat 
A hard hat is certainly one of the most noticeable pieces of safety equipment one 
can identify in the industrial workplace. It’s an industrial helmet to protect you 
from falling objects and impacts by sharp or blunt things. In America itself, more 
than 20 Million workers wear hard hats at work, yet the numbers of accidents 
reported per year are approximately 120,000. Such a staggering figure represents 
on the job head injuries only, out of which 1500 are almost fatal. 
From the above figures, we can understand that it is arguably the most essential 
equipment for workers to ensure personal safety at any industrial site. Features 
of a comfortable hard hat are durability, reliability, ruggedness and lightweight 
and manufacturers often consider various factors in building them as not all of 
them are suitable for every type of work climate. Hard hats come in different 
types and are categorized in classes so that employers and employees can 
determine the best suitable hard hats as per their work environment.
Materials used to make them 
Most of the hard hats including hard hat accessories are manufactured nowadays 
with the use of advance technology and are results of well researched and 
experimented practice. The core shells are made up of thermoplastic like 
Polyethylene or Polycarbonate resin or materials like fiberglass or aluminum. 
High-density Polyethylene better known as HDPE are mostly used in hard hats as 
they are nonconductive to electricity as well are strong and light in weight. The 
suspension system in the hard hats that distribute the impact of the blow to the 
other edges are made of strips of woven nylon webbing and molded HDPE bands. 
These bands are sometimes of nylon or vinyl. 
A comfortable hard hat will also feature a brow pad. These brow pads are 
attached to the front of the headband as it increases the comfort level of the 
helmet. The materials used to make up the brow pads differ depending on the 
manufacturer but are mostly of foam supported vinyl, cotton terry cloth or 
sometimes of special fibers. Most of the manufacturers, however, select varying 
mixtures of cloth material with cotton as it augments the helmet’s ability to 
absorb sweat. Sometimes, it also helps in avoiding irritants while at work. 
Make of other hard hat accessories 
Depending upon the use and the work climate, hard hat liners are also available in 
different materials. Cotton, Nylon and polyester made liners make a great 
demand and are an efficient protective gear against cold, flame and extreme 
conditions. OSHA (The Occupational Safety and Health Administration) in its 
guidelines suggests that an employer should check with manufacturers whether 
use of liners with their hard hats/hard hat msa’s is compatible. They recommend 
employers to check the same with the hard hat manufacturers as well. Other 
accessories like hard hat decals and stickers may not concern us with their quality 
and material but, they have a crucial role in safety and precaution at workplace. 
Decals and stickers are part of any safety program as they add visibility and help 
us to identify skilled employees. They can carry important safety reminders and 
can promote employer’s safety awareness program. In cases of emergencies, it 
helps us to identify trained and authorized safety personnel instantly and help us
to assign the job quickly. Ideal and an inexpensive way of communicating safety 
to employees, decals and stickers are mostly available in sensitive vinyl or 
engineer grade reflective as it increases low light or nighttime vision. 
Hatgrabber offers a variety of hard hat accessories designed to keep you 
comfortable and protected while you wear your hard hat. Find more information 
to http://hatgrabber.com/ or feel free to call us at 479-250-0107.

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How hard hats are made

  • 1. Here's What Goes Into Making A Strong Hard Hat A hard hat is certainly one of the most noticeable pieces of safety equipment one can identify in the industrial workplace. It’s an industrial helmet to protect you from falling objects and impacts by sharp or blunt things. In America itself, more than 20 Million workers wear hard hats at work, yet the numbers of accidents reported per year are approximately 120,000. Such a staggering figure represents on the job head injuries only, out of which 1500 are almost fatal. From the above figures, we can understand that it is arguably the most essential equipment for workers to ensure personal safety at any industrial site. Features of a comfortable hard hat are durability, reliability, ruggedness and lightweight and manufacturers often consider various factors in building them as not all of them are suitable for every type of work climate. Hard hats come in different types and are categorized in classes so that employers and employees can determine the best suitable hard hats as per their work environment.
  • 2. Materials used to make them Most of the hard hats including hard hat accessories are manufactured nowadays with the use of advance technology and are results of well researched and experimented practice. The core shells are made up of thermoplastic like Polyethylene or Polycarbonate resin or materials like fiberglass or aluminum. High-density Polyethylene better known as HDPE are mostly used in hard hats as they are nonconductive to electricity as well are strong and light in weight. The suspension system in the hard hats that distribute the impact of the blow to the other edges are made of strips of woven nylon webbing and molded HDPE bands. These bands are sometimes of nylon or vinyl. A comfortable hard hat will also feature a brow pad. These brow pads are attached to the front of the headband as it increases the comfort level of the helmet. The materials used to make up the brow pads differ depending on the manufacturer but are mostly of foam supported vinyl, cotton terry cloth or sometimes of special fibers. Most of the manufacturers, however, select varying mixtures of cloth material with cotton as it augments the helmet’s ability to absorb sweat. Sometimes, it also helps in avoiding irritants while at work. Make of other hard hat accessories Depending upon the use and the work climate, hard hat liners are also available in different materials. Cotton, Nylon and polyester made liners make a great demand and are an efficient protective gear against cold, flame and extreme conditions. OSHA (The Occupational Safety and Health Administration) in its guidelines suggests that an employer should check with manufacturers whether use of liners with their hard hats/hard hat msa’s is compatible. They recommend employers to check the same with the hard hat manufacturers as well. Other accessories like hard hat decals and stickers may not concern us with their quality and material but, they have a crucial role in safety and precaution at workplace. Decals and stickers are part of any safety program as they add visibility and help us to identify skilled employees. They can carry important safety reminders and can promote employer’s safety awareness program. In cases of emergencies, it helps us to identify trained and authorized safety personnel instantly and help us
  • 3. to assign the job quickly. Ideal and an inexpensive way of communicating safety to employees, decals and stickers are mostly available in sensitive vinyl or engineer grade reflective as it increases low light or nighttime vision. Hatgrabber offers a variety of hard hat accessories designed to keep you comfortable and protected while you wear your hard hat. Find more information to http://hatgrabber.com/ or feel free to call us at 479-250-0107.