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Hard Hats in the Theatre: Safety, Compliance, and Color Codes
Hard hats aren’t just for construction sites; they’re an essential part of personal protective equipment (PPE) backstage in theaters and performing arts venues. With the frequent use of overhead rigging, temporary lighting structures, fly systems, and heavy equipment being moved during load-ins and strikes, there are many opportunities for head injuries. OSHA regulations require protective helmets in workplaces where such hazards exist, and theatres are no exception.
When Hard Hats Are Required in Theatres
Under OSHA’s general industry standard 29 CFR 1910.135, employers must ensure that employees wear head protection when there’s a potential for injury from falling objects or from contact with electrical hazards. This regulation applies to any setting where work is being performed overhead or where elevated tools, scenery, or equipment are in use.
For theatres, this often includes:
- Load-ins and load-outs
- Focus calls with overhead lighting instruments
- Scenery and fly system operations
- Onstage or grid-level rigging work
- Construction or scene shop activities
- Walking under decks
According to OSHA, a hazard assessment must be conducted under 29 CFR 1910.132(d) to determine PPE requirements. If the assessment identifies risks of falling or flying objects, hard hats become mandatory.
Many venues have the following policy to comply with OSHA Codes: Any time riggers are above the stage, hardhats must be worn. Any time Battons or other items are moving or flown below 7′ hardhats must be worn. Naturally this does not typically include performances and rehearsals.
Employer Responsibilities
Employers are responsible for providing hard hats free of charge to employees when required by the work environment (29 CFR 1910.132(h)). This includes ensuring that hard hats:
- Comply with ANSI/ISEA Z89 (latest revision)
- Are maintained in a sanitary and reliable condition
- Are properly stored to prevent exposure to damaging elements such as UV rays, extreme heat, or chemicals
- Are regularly inspected for damage or deterioration
- Are replaced immediately if they sustain an impact, even if no damage is visible
Storage and Cleaning of Hard Hats
Hard hats should be stored in a cool, dry location out of direct sunlight. UV degradation from stage lights or sun exposure can weaken the shell, making it less effective. Avoid placing hard hats on dashboards, near windows, or under equipment that could deform their shape.
Cleaning should be done with mild soap and warm water. Do not use solvents, petroleum products, or harsh chemicals, as these can compromise the structural integrity of the shell and suspension system. Most manufacturers recommend removing the suspension and washing it separately.
Suspension systems should also be inspected regularly. Over time, the straps can wear out or lose elasticity, affecting the hard hat’s ability to absorb impact.
Hard hats should not be thrown in a bin and sprayed with Lysol before each use.
Here’s why:
1. Deformation Risk
Throwing hard hats into a bin can cause physical damage like cracks, dents, or distortion—especially if other gear or weights are tossed on top. Any structural damage can compromise the helmet's ability to absorb impact, rendering it unsafe.
2. Chemical Degradation
Lysol and similar disinfectant sprays often contain alcohols, ammonia, or petroleum-based solvents, which can degrade the plastic shell or suspension system over time. This can lead to brittle shells or weakened straps that will not perform during an impact.
3. Manufacturer Guidelines
Most PPE manufacturers (e.g., 3M, MSA, Bullard) specifically instruct users to:
Avoid harsh chemicals or disinfectants
Clean hard hats with mild soap and warm water
Inspect helmets after cleaning for any degradation
For example, 3M (2022) states:
“Use only mild soap and warm water to clean the shell. Disinfectants may damage the shell and are not recommended unless explicitly approved.”
4. OSHA Compliance
Improper storage and maintenance can violate OSHA’s PPE rules under 29 CFR 1910.132 and 1910.135, which require that PPE be:
"Maintained in a sanitary and reliable condition"
"Repaired or replaced as needed to ensure effectiveness"
Correct Method for Group Cleaning:
If you're trying to clean and reuse hard hats for multiple people (e.g., in a theater load-in situation), use the following procedure:
Visually inspect each hard hat first. Discard damaged ones.
Use a mild soap and water solution with a clean cloth or sponge to wipe the surface.
Use manufacturer-approved disinfectant wipes if disinfection is required. Some brands (e.g., Clorox Healthcare® Hydrogen Peroxide Wipes) may be approved.
Allow helmets to air dry fully.
Store in a clean, dry, structured container (not a pile or trash bin).
Color Coding of Hard Hats in Theatres
While not mandated by OSHA, many venues use color-coded hard hats to quickly identify personnel roles during high-risk work. Here are typical color assignments adapted from industrial and live event practices:
- White: Managers, technical directors, supervisors, safety officers, stewards, department heads
- Yellow: General crew, carpenters, electricians, laborers, Crew, Lighting, Pushers
- Blue: Communications based crew, Audio, sound techs, Video,
- Green: Safety personnel or observers
- Red: Fire watch or designated first responders, Pyro
- Orange: Spotters, traffic controllers, or fly rail operators, riggers
- Gray or Black: Stagehands (commonly seen in theatrical settings for low visibility under lights)
- Pink: Often used as a loaner and by women to boost morale.
These assignments may vary by venue, production company, or local union agreement, but a consistent color system improves communication and visibility, particularly during load-ins and strikes.
It’s also possible each crew (Carpenters, Lighting, Video, Audio, Pyro, Backline. Pushers, etc.) to be assigned a unique color.
Use of Stickers and Customization
Stickers are frequently used in theatre environments to identify departments, unions, certifications, or to personalize equipment. OSHA allows their use, provided they don’t compromise the integrity of the hard hat.
Key guidelines for sticker use:
- Stickers must not cover areas subject to impact or obscure cracks and defects
- Adhesives should be non-petroleum-based and recommended by the manufacturer
- Stickers should be applied sparingly and only after the helmet has passed inspection
- Metal or reflective stickers should be avoided unless approved for the model
MSA, Bullard, and 3M all advise against excessive sticker use that could interfere with inspections or degrade the shell material. ANSI Z89.1-2014 does not prohibit stickers but reinforces the requirement that helmets be maintained in a condition that allows for visual inspection and compliance.
Some employers require stickers for empoyeers who have completed safety training. These stickers when procured through common industry suppliers, typically comply with manufacturer recommendations.
Distribution and Training
The employer must ensure that all employees:
- Receive a properly fitted hard hat that matches their role
- Are trained in the care, inspection, and replacement of head protection
- Understand the limitations of the equipment (e.g., not for lateral impact unless labeled Class G or E)
Hard hats should never be shared between employees unless properly cleaned and reissued. Lost or damaged hard hats should be replaced promptly, with clear tracking of who has been issued which unit.
The use of hard hats backstage is a critical safety measure that aligns with OSHA regulations and theatrical industry best practices. By conducting proper hazard assessments, supplying compliant equipment, maintaining clear identification through color coding, and following manufacturer guidelines on maintenance and labeling, theatre employers can protect their crews and create a culture of safety that meets both regulatory and professional expectations.
References
3M. (2022). Head protection technical bulletin: Proper care and use of hard hats. Retrieved from https://multimedia.3m.com
MSA Safety. (2023). Protective headwear – Use and care manual. Retrieved from https://us.msasafety.com
Occupational Safety and Health Administration. (2024). 29 CFR 1910.135 – Head protection. U.S. Department of Labor. https://www.osha.gov/laws-regs/regulations/standardnumber/1910/1910.135
Occupational Safety and Health Administration. (2024). 29 CFR 1910.132 – General requirements for personal protective equipment. https://www.osha.gov/laws-regs/regulations/standardnumber/1910/1910.132
Occupational Safety and Health Administration. (2009, June 12). Letter of interpretation: Use of adhesive stickers on hard hats. https://www.osha.gov/laws-regs/standardinterpretations/2009-06-12
ANSI/ISEA Z89.1-2014. American National Standard for Industrial Head Protection. International Safety Equipment Association.