Hard Hat Accessories, Stickers & Liners
Workers customize hard hats with stickers, lights, face shields, ear muffs, liners and straps. Some additions are fine and some quietly ruin the protection the hat provides. A hard hat is tested as a complete product. Anything you drill, paint or glue on can weaken it, and an accessory that isn’t approved for your hat can make it fail when you need it most.
- All Construction Workers
- Industrial Workers
- Supervisors
The basic rule: stay within the maker’s approval
- OSHA requires head protection that meets ANSI Z89.1 (or an equivalent standard). See Hard Hats. The hard hat is tested as manufactured, with its suspension and approved accessories.
- Hat makers publish lists of approved accessories for each model. Accessories that fit the hat’s slots and clips and are listed by the maker have been tested with it.
- Modifications can void the certification and the protection. Drilling holes, cutting, using solvents or adhesives, and adding non-approved parts can weaken the shell or change electrical properties.
- When in doubt, ask the manufacturer and your safety manager, and follow company policy.
Accessories that are commonly okay (if made for your hat)
| Accessory | Purpose | Cautions |
|---|---|---|
| Chin straps | Keep the hat on when working at heights, in wind and when leaning forward | Use a breakaway strap where there is a snag or climbing hazard. Some tasks require a strap. See Fall Protection Basics |
| Brim, sun shield and neck shade | Sun protection and rain | Must clip or fit as designed. See Sun Protection |
| Face shields and visors | Splash, impact, grinding and arc flash | Must mount to the hat’s slots as the maker specifies. Not a substitute for safety glasses. See Eye & Face Protection |
| Ear muffs (slotted) | Hearing protection that mounts to the hat | Use muffs made for that hat. See Hearing Protection |
| Winter liners | Warmth under the hat | Must not reduce the hat’s clearance or fit; use thin liners made for hard hats. See Cold Weather Clothing |
| Cooling pads and sweatbands | Comfort and cooling | Use approved parts and keep clean. See Cooling PPE |
| Lamps and headlights | Light in dark areas | Use lights approved for the hat, and for hazardous locations where needed. See Night Work Lighting |
| Reflective tape | Visibility, especially at night or near traffic | Use tape recommended for the shell |
Stickers, labels, paint and markings
- Stickers: many hard hat makers allow small, pressure-sensitive stickers on the shell, as long as they don’t cover the manufacturer’s labels, and don’t use harsh adhesive. Some companies ban them because they can hide cracks and damage. Check your employer’s rules and the hat maker’s instructions.
- Don’t cover the required labels inside and outside the hat (maker, date, type and class, standard). Don’t cover cracks or damage with stickers.
- Paint and solvents: most makers say not to paint hard hats, since paint solvents can weaken the plastic. If paint is allowed, use only the maker’s recommended paint or tape. Don’t use thinners, gasoline or strong cleaners.
- Markings: use marker pens or labels only as approved. Some inks and adhesives contain chemicals that attack the shell. Sticker color or marking by trade, such as a color for a role or a safety status, should be set by employer policy. See Site Orientation.
- Don’t place metal or conductive stickers or metallic paint on hats worn near electrical hazards. Class E hats are tested for high voltage, and conductive materials can compromise them.
- Be careful with reflective and metallic stickers on hats in electrical areas, and remove stickers before the hat is inspected.
What not to do
- Don’t drill holes or cut vents or slots into the shell, even for lights or straps. Use the existing slots or approved clips.
- Don’t wear a cap, hood, bandana or thick beanie under the hard hat in a way that changes the fit or removes the suspension space. Thin liners made for the hat are OK.
- Don’t wear the hat backward unless the model is rated for reverse wear (many are, and are marked). Check the label.
- Don’t store the hat in a car window or hot place, where heat and UV degrade it. Don’t leave a hard hat in the sun on the dashboard.
- Don’t use tape, glue or adhesives on the shell, unless approved by the maker.
- Don’t use the hat as a seat, bucket or to carry tools.
- Don’t mix parts from different hat brands or models, especially suspensions.
Inspection and replacement
- Inspect the hat before each use: look for cracks, dents, gouges, chalky or faded surface, brittleness, worn or frayed suspension and sweatband, and damaged accessories. Flex the shell gently to check for cracks. See PPE Inspection & Care.
- Replace the hat after any heavy impact, even if there is no visible damage, since it may be damaged internally.
- Replace the suspension and sweatband at the maker’s intervals, often every 12 months for suspensions, and the shell on the maker’s schedule, typically about 5 years, or sooner in harsh conditions. Check the date stamped inside the shell.
- Clean with mild soap and water, not solvents. Let the hat air dry.
- Replace damaged accessories and keep only approved ones. See PPE Hazard Assessment.
Hard hat add-on checklist
- My accessories are made and approved for my exact hard hat model
- I haven’t drilled, cut, glued or painted the shell, and my stickers follow maker and employer rules
- Required labels are visible, and nothing covers cracks
- I wear a thin approved liner in cold weather, and a chin strap when working at heights or in wind
- I inspect the hat before each use and replace it after an impact or when it is out of date
- I store the hat out of heat and sunlight
Standards & references
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