When was the last time you properly checked your hard hat? On busy construction sites, it’s easy to overlook small cracks or worn straps, but these minor faults can lead to serious head injuries. That’s why regular helmet checks are critical for your safety.
With Hard Hat Awareness Week 2025 (9–15 June) shining a spotlight on site safety, this helmet inspection checklist for the UK will walk you through exactly what to check before every shift, what to do after any impact, when to replace your helmet, and how to extend its lifespan.
The importance of routine hard hat checks
Every year, workers suffer serious head injuries that could have been prevented by a simple helmet check. Hard hats are designed to take the impact, but only if they’re in good condition. Cracks, dents or worn straps can leave you exposed without realising it.
Following the right hard hat inspection steps can make all the difference. Taking a couple of minutes before each shift helps you catch problems early, before they put you at risk.
Sadly, many workers wear helmets that are damaged or past their best without knowing it. By following a helmet inspection checklist, you’re giving yourself the best chance to spot those issues early and stay protected.
Pre-shift inspection
Before you start work, take a moment to give your hard hat a proper once-over. Small signs of wear can quickly become serious if left unchecked. Here’s how to inspect a hard hat before each shift to help prevent avoidable injuries.
Check the shell for cracks, dents & deformation
Start with a full visual check of the outer shell. Look for any cracks, dents, splits or deep scratches. Even small deformations can weaken the helmet’s ability to absorb impact. Run your hand over the surface to feel for any soft spots or warping that aren’t immediately visible.
Inspect suspension system & chinstrap
Next, check inside the helmet. The suspension system – the webbing or straps that hold the helmet on your head – should be secure, undamaged and sitting correctly. Look for frayed straps, loose fittings or broken clips. If your helmet has a chinstrap, make sure it fastens securely and hasn’t lost tension.
Verify certification stickers & expiry dates
Finally, check the manufacturer’s label. Every hard hat should display its certification and production date. Most have a recommended lifespan of 2 to 5 years, depending on use and exposure. If the helmet is beyond its service life or missing its sticker, replace it immediately.
Post-impact inspection
Even if your helmet looks fine after a knock, unseen damage can weaken its protection. After any impact (no matter how minor), it’s essential to carry out a thorough check before using the helmet again. Here’s a quick post-impact helmet inspection guide to help you stay safe.
Rotate the shell 90° to reveal hidden cracks
Hard hats are often struck at an angle, which can create stress points not visible from a straight-on view. Gently rotate the shell and inspect it from different angles under good lighting. Look for fine cracks, hairline fractures or subtle warping that might not show from one position.
Document helmet damage & incident details
If you spot any damage, document it immediately. Note the time, location and nature of the impact, and take photos where possible.
Reporting the incident to your supervisor ensures proper records are kept — important for both site safety and any future injury claims under regulations like RIDDOR (Reporting of Injuries, Diseases and Dangerous Occurrences Regulations).
Learn more about what to do after a head injury on site.
Assess any concussion symptoms
After a blow to the head, always check for signs of concussion. Symptoms may include dizziness, headaches, nausea, blurred vision or confusion. If you experience any of these, seek medical attention right away, even if you feel fine initially.
How to tell it’s time for a new hard hat
Even with regular checks, every hard hat has a limited lifespan. Knowing when to replace yours is a vital part of staying safe on site.
Manufacturer’s replacement guidelines (2–5 years)
Most manufacturers recommend replacing hard hats every two to five years, depending on use. Check the production date printed inside your helmet. This gives you a clear idea of its service life. If you’re unsure, err on the side of caution and replace sooner rather than later.
Environmental factors that accelerate degradation
Exposure to harsh conditions can shorten your helmet’s lifespan. Sunlight, extreme temperatures, chemicals and rough handling can all weaken the materials. If your helmet has faded, become brittle or shows signs of surface wear, it may no longer offer full protection.
Replace even after minor bumps
Even small impacts can cause internal damage you can’t see. If your helmet has taken a knock, always follow post-impact inspection steps. When in doubt, replace it — it’s never worth the risk.
Best practices to extend the life of your hard hat
With a bit of care, you can help your helmet stay safe and effective for as long as possible:
- Avoid heat and sunlight: Don’t store your helmet on dashboards, radiators or in direct sunlight. Excess heat can weaken the plastic over time.
- Keep it clean: Wash with mild soap and warm water. Avoid abrasive cleaners or solvents that can damage the shell.
- Skip the stickers and paint: Adhesives and chemicals may weaken the helmet material.
- Store safely: When not in use, keep your helmet in a cool, dry place away from heavy objects.
For more advice on helmet types and impact protection, see our guide: Rotational vs. linear impact: choosing the right hard hat.
Stay safe onsite
Bookmark or print this helmet inspection checklist and share it with your team. For more construction safety advice and legal support, our friendly team is here to help.
And if you ever need to make a claim, we operate on a no win no fee basis, so there’s no financial risk in getting the help you need. If you’ve already suffered an injury at work, use our compensation calculator to see what you may be entitled to.
FAQs
What are the top hard hat safety tips everyone should follow?
Always check your helmet before each shift. Look for cracks, dents or wear inside and out. Replace it after any impact, store it away from heat or sunlight, and never use paints, stickers or solvents that could weaken the material. Follow manufacturer guidelines for lifespan and care.
What’s the difference between a hard hat and a safety helmet?
Hard hats are the traditional option, mainly protecting against falling objects. Safety helmets often offer extra side-impact protection, better stability and more secure chinstraps – especially useful for work at height or with moving machinery. The right choice depends on your job’s specific risks and requirements.
How do I choose the right hard hat for my job?
Start with a helmet that meets UK or EU certification standards. Consider impact type (top and side), job site hazards, comfort, ventilation and fit. If you’re working at height or near moving equipment, a safety helmet with a chinstrap may offer better protection.