The construction engineering firm Clayco is vetting manufacturers to produce what it’s calling the “hard hat of the future,” which Clayco has developed with a team of 14 students and two faculty members at the Savannah (Ga.) College of Arts and Design (SCAD).
The global hard-hat market is expected to hit $3.19 billion in sales in 2025, from $2.1 billion in 2016. Clayco has been investigating improvements in hard-hat design for more than a year, starting with a evaluation of different design trends worldwide. “We concluded that we might be better off designing a new helmet ourselves,” says Todd Friis, Clayco’s Vice President of Risk Management.
Clayco had been involved in numerous construction projects with SCAD, and also supports the school’s sustainability efforts, says Paul Runko, Collaboration Manager at SCADpro, the school’s industry partnership department.
To gain a better understanding on how construction workers use their hard hats, the students visited Clayco’s jobsite for a 14-story residence hall at SCAD’s Atlanta campus to observe and interview the labor. “For many of our students, this was the first time they had ever put on a hard hat,” says Runko.
SCAD also created an online survey that received 188 responses from workers at various locations around the country.
What the research found was that while existing hard hats are safe, too often workers aren’t wearing them because, they say, the hats are uncomfortable or too hot. What the student team also discovered was how avidly workers personalize their hats, usually with stickers. And many of the workers polled or interviewed wear sunglasses on the job, which can affect the wearability of the helmets.
Charu Pardasani a researcher, planner, and documentarian on the Clayco-SCAD team, says that the students came up with 10 conceptual and abstract ideas, from which they developed eight hard hat concepts. Clayco has selected two prototypes on which to move forward:
Clayco has selected two hard hat designs, The Captain and Pollux, to manufacture. These were chosen from eight concepts. Image: Clayco
Pollux, whose design was based on workers’ need for adaptability. The customizable design allows users to attach a magnetic LED light or mount a GoPro camera. Pollux has a rotatable, transparent full brim that provides shade and visibility. The prototype includes a chin strap, not exactly a feature workers were clamoring for, but one that is included to enhance users’ comfort and to keep the hats on their heads, especially in high-wind situations.
Captain, the second prototype, features a completely different design. It’s more like a helmet, with vents at the top and the brim. This hat also has portals for multiple accessory attachments.
Friis says that, in choosing these two models, Clayco considered weight, ventilation, lighting, and attachments. (Neither of the prototypes has a face shield, but one can be attached to each.) He adds that Clayco paid particular attention to back-of-head protection during the design phase.
The cost of the new hard hats, and when they might be available for sale, has yet to be determined. Runko notes that during the 10-week design period, a group of students was dedicated to selecting materials with an eye toward affordability.
Clayco’s involvement can be seen as part of its broader effort to improve jobsite safety. That effort got a boost from a $1 million five-year grant that Clayco and the Washington University School of Medicine in St. Louis received from the National Institute of Occupational Safety and Health and CPWR The Center for Construction Research and Training.
In 2013-2014, Clayco and the school had conducted a study of three of Clayco’s jobsites in St. Louis to observe and measure how ergonomic programs were being administered and complied with. Ann Marie Dale, an Associate Professor at the medical school, explains that ergonomic injuries occur over time from the gradual and repetitive wear and tear on the body. They can include such injuries as lower-back strain, rotator cuff tears, and trigger finger deterioration.
After seeing the results of this survey, Dale and Friis met in the spring of 2017 to discuss “interventions” that might help reduce such injuries. A program for that purpose was rolled out to all of Clayco’s job sites over the course of the following year. Dale and her team continued to monitor progress at the three “control” jobsites in St. Louis. (She was accompanied on jobsites by ergonomics experts who could answer workers’ questions.)
Dale says that it took longer than anticipated to develop the safety literature to disseminate to the jobsites, as well as a training regimen. “This is not going to be a quick fix,” she concedes. Friis declined to disclose specific data about jobsite safety except to say that, as of May 2019, three-quarters of Clayco’s active construction projects were injury-free. “It’s not perfect, but the results speak for themselves.”
Dale adds that there is interest among other construction companies to adopt the Model program that UWash and Clayco have developed.
Related Stories
| Jan 30, 2014
See how architects at NBBJ are using computational design to calculate the best views on projects [video]
In an ideal world, every office employee would have a beautiful view from his or her desk. While no one can make that happen in real life, computational design can help architects maximize views from every angle.
| Jan 30, 2014
The evolving workplace: One designer's inspiration board
"Open office" has been a major buzzword for decades, and like any buzzword, some of the novelty has worn off. I don't believe we will abandon the open office, but I do think we need to focus on providing a dynamic mix of open and closed spaces.
| Jan 30, 2014
How reverse engineering nature can spur design innovation
It’s not enough to copy nature. Today’s designers need a deeper understanding of environmental nuance, from the biome in.
| Jan 30, 2014
What to expect in the metal building industry in 2014
Every year brings changes. This one won’t be any different. We’ll see growth in some areas, declines in others. Here’s a little preview of what we’ll be writing about 2014 when 2015 comes rolling in.
| Jan 30, 2014
What's in store for healthcare capital markets in 2014?
Despite the shake up stemming from the Affordable Care Act, 2014 will be an active year in healthcare capital markets, according to real estate experts from CBRE Healthcare.
| Jan 29, 2014
Richard Meier unveils 'urban courtyard' scheme for Mexico City towers
A grand atrium, reaching some 30 stories, highlights the contemporary, bright-white design scheme unveiled this week by Richard Meier & Partners for a new mixed-use development in Mexico City.
| Jan 29, 2014
Hotel, retail, recreation sectors to lead growth in 2014
AIA's Consensus Construction Forecast, a survey of the nation’s leading construction forecasters, is projecting that spending will see a 5.8% increase in 2014, led by the hotel, retail, and amusement/recreation sectors.
| Jan 29, 2014
Notre Dame to expand football stadium in largest project in school history
The $400 million Campus Crossroads Project will add more than 750,000 sf of academic, student life, and athletic space in three new buildings attached to the school's iconic football stadium.
| Jan 28, 2014
White Paper: How metal buildings deliver long-term value to schools
A new white paper from Star Building Systems outlines the benefits of metal buildings for public and private school building projects.
| Jan 28, 2014
First Look: BIG's Honeycomb building for Bahamas resort [slideshow]
BIG + HKS + MDA have unveiled the design for the new Honeycomb building and adjacent plaza in The Bahamas – a 175,000-sf residential facility with a private pool on each balcony.