The Best Hard Hats and Construction Safety Helmets 2024: A Comprehensive Review

Ensuring the safety of construction workers is a top priority at any job site, and one of the most crucial components of that safety is the use of a hard hat, or, increasingly, the construction safety helmet. In 2024, there are now several new types of safety helmets that offer significantly more protection versus the traditional hard hat. 

The traditional hard hat is no longer the safest way to protect the brain and head on the job. Hard hat technology had remained practically unchanged for more than 100 years, with little innovation beyond the material of the shell. Hard hats are primarily designed to protect the top of the head from falling material, but this type of injury represents a much smaller percentage of actual workplace incidents compared to trips, slips, and falls. According to the U.S. Bureau of Labor Statistics, falls, slips, and trips were the leading cause of fatalities in the construction industry, accounting for 37.9 percent of all fatalities from 2015 to 2019. In comparison, deaths from falling objects represented just 16.7 percent of cases.

Therefore, industrial workers in construction, manufacturing, oil and gas, utilities, and mining industries are requiring new types of headwear that provide full, 360-degree head protection to better protect against  falls, trips, and slips along with the traditional protection against falling objects. 

Type 1 Versus Type 2 Safety Helmets 

In North America, most hard hats today are primarily designed to comply with the American National Standard for Industrial Head Protection (ANSI) Z89.1 Type I standard. However, this standard only accounts for protecting injuries from falling objects, not falling workers. In response, ANSI developed the Z89.1 Type II standard. 

ANSI-certified Type II safety helmets incorporate advanced shock-absorbing technologies and offer front, side, and rear impact protection. Additionally, they often feature chin straps and other innovations, such as near-field communication (NFC) chip technology that digitally embeds the medical ID of the wearer into the helmet. This offers easier access to first responders to gather critical medical information, such as medical allergies or emergency contact details, to provide better and faster care should the wearer become incapacitated. 

It is also important to consider the other key advantages of Type II safety helmets: 

• Durability: Well-designed and robust structures enhance the longevity of safety helmets, diminishing the necessity for frequent personal protective equipment (PPE) replacement.
• Financial Incentives: A decline in injuries results in fewer worker compensation claims, potentially leading to significant cost savings for organizations. 
• Diminished Liability Insurance Expenses: Reducing injuries may reduce liability insurance costs for businesses.
• Risk Mitigation: Adopting Type II safety helmets promotes a safety-oriented culture on the job site, contributing to a decrease in workplace hazards overall.
• Productivity: With fewer injuries, workers can allocate more time to tasks on the job site and less time to recovery, potentially elevating productivity and earnings.

What to Look for When Buying a Construction Safety Helmet

Prioritize Safety Standards

When investing in a construction helmet, it is crucial to adhere to the rigorous safety standards for PPE Equipment to ensure the helmet's effectiveness in providing optimal protection. Regulatory bodies such as OSHA (Occupational Safety and Health Administration) in the United States and ANSI establish strict guidelines to ensure the quality and performance of safety helmets. 

It is imperative to choose a construction helmet that meets or exceeds these standards, as this certification indicates that the helmet has undergone rigorous testing and complies with industry-specific safety requirements. Checking for certifications not only ensures legal compliance but also instills confidence that the selected helmet has been designed and manufactured to withstand the potential hazards of the work environment, ultimately safeguarding the wearer against head injuries.

Safety Technology

Twiceme HTH-Technology

Twiceme’s Help the Helpers Technology is an integrated technology based on secure NFC and encourages bystanders to become helpers in the event of an accident. By tapping the NFC antenna of your phone onto the Twiceme symbol on the helmet, bystanders can access the medical information of the wearer, alert ICE contacts/emergency personnel, and send the precise location of the helmet-wearer. Learn more at twiceme.com/emergency.

It also empowers workers to engage in preventative measures, such as inspecting the health of the equipment, performing routine product inspections, and informing about safety measures to customers. Utilizing a guided system that stores inspection data digitally not only helps the workforce understand if their respectivePPE is adequate or not, but it also helps safety managers better manage the inventory for planned obsolescence and replacement programs. 

Read more at twiceme.com/non-emergency.

Integrated Impact Technology

MIPS

A technology integrated into helmets, that is designed to reduce rotational motion to the head during oblique impacts. The MIPS design incorporates a low-friction layer between the outer shell of the helmet and the inner padding. During an angled impact, this layer allows a controlled rotation of the outer shell relative to the head, mimicking the brain’s own protective mechanisms. This rotation helps to redirect and disperse rotational energy, reducing the strain on the brain and lowering the risk of certain types of traumatic brain injuries (TBIs), such as concussions. 

Koroyd

An impact technology built into helmets that consists of a network of small cylindrical tubes or a honeycomb-like structure. Upon impact, the Koroyd structure compresses rapidly and in a controlled manner, crumpling the tubes. This controlled deformation absorbs and disperses the energy generated by the impact, reducing the force transmitted to the head. The collapsible nature of the tubes allows for a more gradual speed reduction, which can be beneficial in reducing the risk of injury.

Comfort

Comfort is a vital aspect to consider when purchasing a construction helmet, as the willingness of the workers to consistently wear their helmet is closely tied to how comfortable it feels during an extended period of time. A well-designed and comfortable helmet minimizes the likelihood of user discomfort, reducing instances of users removing or adjusting their helmets in hazardous work environments. This not only ensures continuous protection but also fosters a positive safety culture on the job site. A comfortable helmet with features like adjustable suspension systems and ventilation enhances wearer satisfaction, promoting long-term adherence to safety protocols.

Materials used within a helmet can play a major role in how comfortable a helmet feels throughout the workday. For example, the Koroyd tubular structure can significantly reduce the weight of a helmet without sacrificing safety. It also provides for more airflow, helping to keep the worker cool during hot weather and preventing the adverse effects of heat stress. According to test results, Koroyd integrated industrial safety helmets show a heat index reduction of up to 4.5°C / 8°F in comparison to traditional EPS foam head protection. Find more details about the study here: https://koroyd.com/heatstress 

Chin Straps 

An effective chin strap harness is critical to ensuring a helmet stays on the head in the event of a slip, trip, or fall. According to the United States Bureau of Labor Statistics, most of these slip-, trip-, and fall-related head injuries happen from only two meters (six feet) or less. 

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For this reason, safety leaders and workers are selecting safety helmets with chin straps, an uncommon safety feature for traditional hard hats. To keep the helmet comfortably on the head during physical activity, Leading safety helmets utilize four-point chin harnesses adopted from action sports to keep the helmet on the head without sacrificing comfort. 

The Best Construction Helmets to Buy 

Zero Pinnacle Zertec

The Zero Pinnacle Zertec helmet stands as a pinnacle of safety for professionals engaged in work at height across various commercial trades. This construction helmet stands out for its cutting-edge Zertec impact-absorbing technology. The Zertec material, a patented innovation, is designed to absorb and disperse impact energy more effectively than traditional materials. The multi-point adjustable suspension system ensures a personalized fit, and the integrated ventilation channels contribute to wearer comfort. The addition of reflective elements enhances safety in various work environments.

Key features: 

• Material: ABS Advanced Thermo Material Shell exterior, high-density EPS polystyrene, integrated Koroyd co-polymer engineered core.
• Suspension system: Multi-point adjustable suspension for a secure and comfortable fit.
• Ventilation: Integrated ventilation channels for improved airflow.
• Additional features: Reflective elements for enhanced visibility in low-light conditions.
• Certifications: EN 12492, EN397, and ANSI Z89.1:2004. Class C. 
• Integrated technologies: Koroyd and Twiceme HTH-Technology.

Studson SHK-1 Full Brim 

The STUDSON SHK-1 Full Brim safety helmet has become a trailblazer in the North American market. It paves the way as the first industrial safety helmet to utilize head-protection components used in gravity sports within the full-brim form factor preferred by those involved in civil construction projects. Along with providing more protection from the elements, the rotational padding of this construction helmet is unique in that it is the first in the industry with silicone shearing pads that allow for rotational energy absorption upon oblique impacts. The innovative padding of this construction helmet is equipped with a silver antimicrobial fiber finish to reduce bacteria. It also features KOROYD lightweight welded tube polymer to better protect against angled impacts and provide for greater airflow in the vented (Class C) version. This safety helmet combines durability with breathability. The optional accessory slots provide versatility for additional safety gear for instance the SHK-1 Half Shield w/Mechanism, the Ear Defender, and the SHK-1 Headlamp. 

Key features: 

• Material: EPS liner and ABS shell for ultimate durability.
• Suspension system: Fidlock magnetic buckle enclosure with adjustable nylon 4-point strap.
• Ventilation: Vented design for enhanced breathability. 
• Additional features: Optional accessory slots for face shields or hearing protection.
• Certifications: ANSI Z89.1- 2014 and EN 12492:2012. Class C. Class E.
• Integrated technologies: Koroyd and Twiceme HTH-Technology.

Studson SHK-1 

The Studson SHK-1 emerges as an excellent choice for individuals working in tight spaces. LIke the full-brim version, this helmet is also available in a Class E version for working with electricity, offering a blend of safety and practicality tailored to the unique hazards of this environment. The Class E version provides solid design for maximum protection, crucial when dealing with electrical work where the risk of arc flashes or electrical contact is present. It also reduces exposure to high-voltage conductors and provides up to 20KV of protection, whilst still offering the same rotational padding as its vented counterpart with Koroyd technology inside. STUDSON also provides purpose-built headwear for improved comfort in both cold and hot weather without sacrificing head safety. 

Key features: 

• Material: EPS liner and ABS shell for ultimate durability. 
• Suspension system: Fidlock magnetic buckle enclosure with adjustable nylon 4-point strap.
• Additional features: optional accessory slots for face shields or hearing protection. 
• Certifications: ANSI Z89.1-2014 and EN 12492:2012. Class C. Class E.
• Integrated technologies: Koroyd and Twiceme HTH-Technology.

Guardio Armet

The Guardio Armet has proven to be a standout in the realm of protective headgear. Engineered with a high-impact ABS shell, it provides unparalleled durability, instilling confidence in the wearer within challenging work environments. The four-point adjustable suspension system in this construction helmet ensures a secure and customized fit, offering comfort for prolonged use. This construction helmet was designed to be compatible with other accessories in the Guardio Armet series such as the Theia Visor-series and the VisorFlex Headlamp as well as hearing protection from Guardio, 3M, and Hellberg Safety. 

Key features: 

• Material: ABS EPP, Nylon, PC, Polyester, Silicone and Stainless Steel.
• Suspension system: Four-point adjustable suspension for comfort and stability.
• Ventilation: Unique ventilation design for increased airflow.
• Additional features: Chin strap with quick-release buckle for easy removal. 
• Certifications: EN397:2012. 
• Integrated technologies: MIPS and Twiceme HTH-Technology.

Summary

As we venture through the rest of 2024, these four construction helmets offer a blend of top-of-the-line technology, comfort, and durability. The Zero Pinnacle Zertec impresses with its patented Zertec material, which absorbs and disperses impact with greater efficiency than traditional materials. The Studson SHK-1 helmets provide versatility for different work environments. The Guardio Armet combines high-impact resistance with thoughtful design features. Ultimately, the choice among these construction helmets depends on the specific needs of the helmet-wearer and the challenges of the construction job at hand. 

FAQ - Construction Helmets:

Which type of construction helmet is the safest?

• Type 2 helmets. These helmets offer greater protection from falls, slips, and trips, whereas traditional type 1 hard hats are only rated to protect against falling objects. With falls accounting for more injuries on average compared to falling objects, Type 2 safety helmets offer superior protection in practically any scenario.  

What is the best construction helmet in 2023?

• Read this article to find the best construction helmet in 2023.

What is the purpose of a hard hat?

• Hard hats protect the head in hazardous work environments by safeguarding the wearer from falling objects, impact from fixed objects, electrical shock, and accidental collisions.

What are the three main classes of hard hats?

• Class G (General) hard hats provide insulation up to 2,200 Volts.
• Class E (Electrical) hard hats provide insulation up to 20,000 Volts.
• Class C (Conductive) hard hats are not intended for electrical protection.

What is the meaning of hard hat colors?

• Hard hat colors help identify the worker's position, responsibilities, and/or the training level of the construction worker. Usually helmet colors are determined by the needs and desires of a given organization. It is important to note that hard hat colors are not a legal requirement from OSHA or ANSI.

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