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
| Sep 16, 2010
Green recreation/wellness center targets physical, environmental health
The 151,000-sf recreation and wellness center at California State University’s Sacramento campus, called the WELL (for “wellness, education, leisure, lifestyle”), has a fitness center, café, indoor track, gymnasium, racquetball courts, educational and counseling space, the largest rock climbing wall in the CSU system.
| Sep 13, 2010
Community college police, parking structure targets LEED Platinum
The San Diego Community College District's $1.555 billion construction program continues with groundbreaking for a 6,000-sf police substation and an 828-space, four-story parking structure at San Diego Miramar College.
| Sep 13, 2010
Campus housing fosters community connection
A 600,000-sf complex on the University of Washington's Seattle campus will include four residence halls for 1,650 students and a 100-seat cafe, 8,000-sf grocery store, and conference center with 200-seat auditorium for both student and community use.
| Sep 13, 2010
Second Time Around
A Building Team preserves the historic facade of a Broadway theater en route to creating the first green playhouse on the Great White Way.
| Sep 13, 2010
Palos Community Hospital plans upgrades, expansion
A laboratory, pharmacy, critical care unit, perioperative services, and 192 new patient beds are part of Palos (Ill.) Community Hospital's 617,500-sf expansion and renovation.
| Sep 13, 2010
China's largest single-phase hospital planned for Shanghai
RTKL's Los Angles office is designing the Shanghai Changzheng New Pudong Hospital, which will be the largest new hospital built in China in a single phase.
| Sep 13, 2010
World's busiest land port also to be its greenest
A larger, more efficient, and supergreen border crossing facility is planned for the San Ysidro (Calif.) Port of Entry to better handle the more than 100,000 people who cross the U.S.-Mexico border there each day.
| Sep 13, 2010
Triple-LEED for Engineering Firm's HQ
With more than 250 LEED projects in the works, Enermodal Engineering is Canada's most prolific green building consulting firm. In 2007, with the firm outgrowing its home office in Kitchener, Ont., the decision was made go all out with a new green building. The goal: triple Platinum for New Construction, Commercial Interiors, and Existing Buildings: O&M.
| Sep 13, 2010
'A Model for the Entire Industry'
How a university and its Building Team forged a relationship with 'the toughest building authority in the country' to bring a replacement hospital in early and under budget.