Straight answers to the questions people ask most when choosing and using safety helmets in welding and fabrication work.
What is a safety helmet for, and when do I need to wear one?
A safety helmet (hard hat) protects your head from falling objects, from knocks against fixed objects and from some side impacts. You need one wherever your risk assessment or the site rules say there is a head injury risk, such as construction sites, work under cranes or overhead activity, and areas with low beams or pipework.
A welding helmet protects your face and eyes from the arc, but it does not replace a safety helmet unless it is designed to do both. Check what head protection the site requires and make sure what you wear covers it.
Can I wear a welding helmet and a safety helmet together?
Yes, and there are three common ways to do it. Some welding shields are made to clip onto a safety helmet, so the shield flips up out of the way. Some are combined units, where the welding shield and safety helmet are one product. Others are built so the whole welding helmet can be worn with a separate hard hat.
Compatibility matters. An adaptor or attachment from one make may not fit the helmet of another, so check that the combination is designed to work together and that the head protection is not compromised by the attachment.
What is the difference between a safety helmet and a bump cap?
A safety helmet has a hard shell and an internal harness that spreads the force of a blow, and it protects against falling objects. A bump cap is a lightweight cap that only protects against minor knocks, such as hitting your head on a low beam or machine, and it will not protect you from something falling on you.
If there is any risk of falling objects, a bump cap is not enough. Ask your safety adviser which is needed for your task, because the wrong choice can leave you unprotected.
How should a safety helmet fit and how do I adjust it?
A safety helmet should sit level on your head, fairly low on the forehead, without rocking when you shake your head and without pinching. Most have a harness that adjusts at the back, either with a ratchet wheel or slots, so you can set the size to your head.
Check there is a clear gap between the shell and the harness and that the helmet does not slip over your eyes when you look down. If you wear a cap, hood or hearing protection underneath, adjust it with those in place. Replace sweatbands that have worn out.
Does a safety helmet protect me from weld spatter and heat?
Not necessarily. A standard safety helmet is made to protect against impact, not hot work, and its shell may be damaged by hot metal or strong heat. Some helmets carry an optional marking for molten metal splash, but only helmets marked for it have been tested for it, so check the markings and the maker's instructions for your own helmet.
For welding and cutting, protect your face, head, neck and ears with suitable welding head protection and a hood or cap as well. If the shell shows scorching, distortion or any other heat damage, replace it.
How long does a safety helmet last, and when should I replace it?
A safety helmet does not last forever. Plastic shells age through sunlight, heat, chemicals and general wear, and the harness and sweatband wear out sooner. Many helmets are marked with a date of manufacture, and makers give guidance on how long they should be used.
Replace the helmet straight away after any significant impact, even if there is no visible damage, because it may no longer absorb a second blow. Replace it, too, if it is cracked, deformed, discoloured, chalky or has a worn harness that cannot be replaced. Always follow the maker's instructions.