Head Protection in Hot Weather: Staying Safe While Keeping Cool

PPE considerations to help industrial workers mitigate the impacts of heat stress.

• By Ryan Barnes
• Aug 01, 2024

Temperatures are rising across the United States and the world on average, year after year. Summers especially are becoming hotter and hotter, accentuated by record-breaking heat waves. In fact, according to the National Oceanic and Atmospheric Administration (NOAA), last year was the warmest year since global records began in 1850 at 1.18°C (2.12°F) above the 20th-century average of 13.9°C (57.0°F). This value is 0.15°C (0.27°F) more than the previous record set in 2016. Meanwhile, the 10 warmest years in the 174-year record have all occurred during the last decade (2014–2023). In the United States alone, last summer more than 6,500 daily heat records fell in cities and towns all across the country.

Such temperature increases are affecting the planet in strange ways; animals are changing migration patterns, plants are blooming earlier, and average annual snow coverage is shrinking. The environmental impact is being heavily documented, but what about the effect on the daily lives of workers? More specifically, what impact do rising temperatures have on people who work outdoors during the warm months, especially industrial tradespeople and construction workers?

There’s no question that construction workers and related industries across the United States are feeling the impacts of climate change and heat stress. Heat is the number one cause of weather-related death in the United States, and those working outdoors are disproportionately affected by extreme heat. As reported by the U.S. Bureau of Labor Statistics (BLS), from 2011 to 2021, there were 528 worker-related deaths in the United States due to environmental heat exposure. In the face of rising temperatures, staying cool and safe on construction sites is more crucial than ever–lives depend on it. 

Thankfully, industrial tradespeople, construction workers, and their respective employers are recognizing this trend, and they are planning accordingly, including introducing new types of PPE designed to not just keep workers safe from injury, but safe from the heat. Even during the high summer months, workers must equip themselves with full PPE to ensure they are safe and compliant with their worksite’s respective standards. However, they must also find ways and methods to stay cool on the job. That is why the Occupational Health and Safety Administration (OSHA) launched its Heat Illness Prevention campaign in April 2022 to educate employers and workers on heat hazards and provide resources to keep workers safe. OSHA’s message is simple yet effective, emphasizing water, rest, and shade.

OSHA encourages workers to drink water every 15 minutes and take frequent rest breaks in the shade to cool off. For employers, OSHA emphasizes the need to maintain an effective emergency plan for when a worker shows signs of heat-related illness. This includes training workers on the hazards of heat exposure and how to prevent illness and allowing workers to gradually build up a tolerance for working in heat. 

Furthermore, organizations are proactively looking at adopting PPE that can help increase worker comfort in extreme heat while enabling workers to acclimate, going above and beyond the basic heat stress mitigation requirements of shade, water, and rest. 

How PPE Can Help Keep Workers Cool

On a hot day, the last thing a worker wants to do is wear a safety helmet, or frankly any PPE that will increase discomfort in the heat. But the reality is that construction sites are dangerous places, and head protection is a requirement, even on the hottest of days. In fact, from 2015 to 2019, slips, trips, and falls were the leading cause of fatalities in the construction industry and accounted for 37.9 percent of all fatalities, according to the BLS. Heat can exacerbate slips, trips, and falls, as workers can become disoriented in the heat due to heat stress, making helmet compliance even more important. According to Williams College researchers, accident rates significantly increase from heat shocks. A different study found that heat stress can negatively impact cognitive performance.

Furthermore, in hot weather, a traditional hard hat can create its own microclimate within. Without venting, there is nowhere for the hot air to escape, making the interior feel hotter than the actual temperature outdoors–this is especially a challenge for those required to wear Class E helmets that are not allowed to have vents, primarily those who work around electrical and other high-voltage equipment. 

On top of this, factors such as helmet color and material makeup can add to the perceived heat. So, how can alternative PPE options help keep workers cool while protecting their cognitive functions?

Vented Helmets

For industrial trades, vented helmets are a great way to help keep cool, and with the advent of Type II safety helmets now quickly replacing the traditional hard hat, workers have more and better options. They can wear safer Type II helmets that are also much cooler to wear in the heat in comparison to traditional Type I hard hats. 

Whether the safety helmet interior is composed of Expanded polystyrene (EPS) foam or an alternative impact protection technology, the vents will allow the hot air to more easily escape and allow for fresh, cooler air to make its way in. In short, good ventilation in a helmet can significantly affect how a worker can manage heat on the job site. A good analogy is sweating. In a way, the vents in a helmet allows the helmet to sweat the heat out, just as any person does to help regulate their body temperature. While this may not be an option for specific trades, like electricians, it is an excellent alternative to traditional, non-vented Type I hard hats.

Alternatives to EPS Foam

EPS foam is widely known across the industry for its use in safety helmets to absorb impacts related to head trauma and accidents. However, EPS is like foam insulation and thus offers little ventilation, making the helmet interior hotter during warm weather. 

An alternative to EPS, or as a supplemental material to EPS for impact protection, are technologies that feature a welded cellular tube structure. These technologies are often lighter, absorb more energy, and are more breathable than EPS foam. Due to the hive-like structure, these materials are often lighter in weight and structured to allow greater air flow, further minimizing the impact of the protected layer. 

Within a study concerning industrial helmets and heat stress from Koroyd, the organization found that helmets that incorporate its Koroyd impact protection technology reduced the heat index by up to 8 degrees Fahrenheit (4.5 degrees Celsius) compared to traditional EPS-only internal helmet constructions. Such findings point to how organizations now have greater choice in purchasing safer helmets with technology that can significantly reduce the risk of heat stress. (Editors’ note: Studson incorporates Koroyd impact protection in some of its helmets.)

Cooling Accessories and UV Protection

Beyond the actual construction of the helmet, workers can use above-the-neck cooling and UV accessories to further reduce the impacts of heat stress. Items such as helmet liners with nape covers and cooling towels feature long-lasting, chemical-free cooling technology with UPF-50 sun protection. Workers can simply wet the garments with water thoroughly, wring out any excess water, then snap or wave the accessories to activate the cooling technology, helping workers stay cooler for up to two hours per rinse or longer. The factor of machine washability is always a plus for these new types of cooling garments, enabling the worker to enjoy a more hygienic experience while tackling the heat.

Other accessories to help combat heat stress are neck shades and sun brims. Neck shades can attach directly to one’s helmet and protect one’s neck from harmful UV rays, debris, and dust. Protecting skin from UV rays can be just as crucial in mitigating the effects of heat stress as staying cool, including preventing sunburns, heat rashes, and other sun-induced skin ailments that can also negatively affect a worker’s health and productivity. Sun brims and UV-blocking eyewear can also provide instant protection from UV rays while improving the wearer’s visibility on bright, sunny days or when facing direct sun glare. 

Washable Materials

When workers feel the heat, they’re likely smelling it, too. The scent of sweat built up from the summer might affect worker comfort as much as the heat. Workers and their employers should consider helmets with washable and replaceable pad sets, if possible. Some are made with antimicrobial technology that helps to eliminate odor-causing bacteria on the fabric. If they’re washable, that is ideal for saving money and minimizing the need to continuously buy replacement sets.

Although as individuals we can’t prevent the next debilitating heat wave, there are ways to mitigate the impacts. By considering OSHA’s heat stress tips, assessing alternative PPE options such as vented helmets, cooling accessories, and impact protection technologies, workers can help change their personal experience of working in the heat without sacrificing safety. While a safety helmet might be the last thing an individual wants to wear during the hotter months, there are ways to improve the experience and help regulate body temperature at work for a more productive, safe, and enjoyable workday.

This article originally appeared in the July/August 2024 issue of Occupational Health & Safety.