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
Â
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.
Â
Related Stories
| Dec 30, 2013
Calatrava facing legal action from his home town over crumbling cultural complex
Officials with the city of Valencia, Spain, are blaming Santiago Calatrava for the rapid deterioration of buildings within its City of Arts and Sciences complex.
| Dec 24, 2013
First Look: Calatrava's Sharq Crossing in Doha, Qatar [video]
The government of Qatar has released details of Sharq Crossing, a massive infrastructure project designed by Spanish architect Santiago Calatrava.Â
| Dec 23, 2013
MBI commends start of module setting at B2, world's tallest modular building
The first modules have been set at B2 residential tower at Atlantic Yards in New York, set to become the tallest modular building in the world.
| Dec 23, 2013
First Look: KPF's dual-tower design for Ziraat Bank in Istanbul
Kohn Pedersen Fox Associates (KPF) is designing a new headquarters for Turkey’s largest and oldest financial institution, Ziraat Bank, in a modern, suburban district of Istanbul.Â
| Dec 20, 2013
Top healthcare sector trends for 2014 (and beyond)
Despite the lack of clarity regarding many elements of healthcare reform, there are several core tenets that will likely continue to drive transition within the healthcare industry.Â
| Dec 20, 2013
Must see for the holidays: Architects re-create iconic structures using gingerbread
Gensler, PBK, Page Sutherland Page, and Kirksey were among the firms to compete in the 5th Annual Gingerbread Build-Off.
| Dec 20, 2013
Can energy hogs still be considered efficient buildings? Yes, say engineers at Buro Happold
A new tool from the engineering firm Buro Happold takes into account both energy and economic performance of buildings for a true measure of efficiency.Â
| Dec 20, 2013
Ten spectacular contemporary churches [slideshow]
German building-information provider Emporis compiles a photographic tour of inspirational spaces.
| Dec 19, 2013
NRDC report relates green infrastructure investments to commercial property value [Infographic]
The Natural Resources Defense Council has released The Green Edge: How Commercial Property Investment in Green Infrastructure Creates Value -- a first-ever illustrative and well-documented report that helps demonstrate the value of green infrastructure. It draws from available published material to capture the multitude of tangible, monetizable non-water quality and water quality benefits that green infrastructure investments (trees, rain gardens, and porous pavement, rainwater harvesting cisterns, bioswales, etc.) can unlock for the commercial real estate sector, including commercial property owners and their tenants.
| Dec 19, 2013
Mastering the art of crowd control and visitor flow in interpretive facilities
To say that visitor facility planning and design is challenging is an understatement. There are many factors that determine the success of a facility. Unfortunately, visitor flow, the way people move and how the facility accommodates those movements, isn’t always specifically considered.