Case Study: How a Hard Hat Prevented a Fatal Head Injury on a Construction Site

bansip
Oct 29
2 min read

The Incident: A Near-Fatal Head Injury

On a construction site managed by Brookfield Multiplex, a high-potential incident occurred when a 40mm flogging spanner fell from a height of 23 stories. The spanner struck a lower crane tie, deflecting into a loading bay and hitting a dogman (a ground crew member) on the head. Fortunately, the worker was wearing a hard hat, which absorbed the impact, preventing a fatal injury. The worker suffered a head wound requiring seven stitches, but the potential for a fatality was high if not for the hard hat. WorkSafe Australia

Lesson: Hard hats save lives—but compliance and maintenance are key.

What Could Have Been Done to Prevent This

Here are some suggestive best practices for preventing head injuries:

Use Compliant Hard Hats: Ensure all helmets meet AS/NZS 1801:1997 standards.
Routine Inspections: Regularly check for cracks, dents, or fraying suspension systems.
Proper Fit: Adjust the suspension system for a secure, comfortable fit.
Signage & Reminders: Place visible reminders on-site for PPE policies.
Worker Training: Educate all personnel on proper PPE use and maintenance.

Learn More About Hard Hat Safety →

What Can Be Done Now

Even if your site hasn’t experienced an incident, consider these proactive measures:

Audit Current Hard Hats: Identify non-compliant or damaged equipment.
Introduce / Reinforce Policies: Make PPE use mandatory and visible in site protocols.
Implement Training Programs: Offer short, recurring PPE workshops or toolbox talks.
Use Signage & Safety Decals: Reinforce the message throughout the site.

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Track Inspections Digitally: Use checklists, MS Forms, or mobile apps to record inspections.
Access PPE Training Resources →

Lessons Learned

No Excuses: There is no acceptable reason for not wearing a compliant hard hat on a construction site.
Regular Maintenance: Hard hats should be inspected regularly for damage and replaced as per manufacturer guidelines.
Continuous Training: Ongoing education and reinforcement of safety policies are crucial to maintaining a safe work environment.