Choosing Hard Hat Communication Systems for Jobsites

If you search for hard hat communication systems online, you’ll get a plethora of options to choose from. The hard part is parsing through them all to examine features and know which one is right for your job site.

That can be difficult because many of them look the same and claim to have similar features. But there are major differences, especially if you need a solution for manufacturing teams, road crews or other types of rugged jobs.

Let’s review what to look for in a hard hat communication system for specific scenarios and my recommendation of which one is best for job sites.

Wireless Two-Way Communication

A lot of the hard hat communication systems found online act more like two-way radios than true communication systems. Most require the user to push a button to talk and force each person to wait their turn. If you have a repair crew working on a piece of industrial equipment for hours at a time, they need to stay in constant communication without having to fumble for buttons while also trying to hold tools or adjust components. In this case, having a hands-free wireless headset also becomes a safety feature.

Full Duplex Transmission

Just because a headset system is wireless doesn’t mean that users can talk simultaneously and be heard. To achieve that kind of functionality, a full duplex system is required. And while this type of advanced technology can cost a bit more than some two-way radio or tour guide systems, it’s a must-have feature for certain job sites.

A full duplex communication system allows multiple people to send and receive messages without delays even if they’re several hundred yards away, much like a multi-party phone conversation. Free-flowing, hands-free communication is critical for highly interactive teams who need to relay urgent instructions, coordinate tasks, or alert teammates to hazards. Real-time communication helps team members respond faster and stay focused on the job at hand. For crews dealing with complex, fast-paced tasks, full duplex communication systems greatly improve productivity, situational awareness and safety.

Example of a Full Duplex System in Action

Six team members of a repair crew at a manufacturing plant need to work nonstop and stay in constant communication for four hours while fixing a large piece of industrial equipment. When testing their repairs, they also need to have two crew members stationed farther down the production line. They’re able to speak and hear in real-time and work hands-free without having to go back and forth or ask other crew members to repeat themselves. Using the full duplex system allows them to get the work done faster, enhance safety and reduce frustrations.

Noise Reduction

High-noise environments include industrial manufacturing floors, construction, mining sites or public works projects that use heavy machinery. Other professions with loud work environments might include arborists or linemen where chainsaws and woodchippers easily drown out conversations and could cause hearing loss over prolonged periods. 

For these scenarios, I recommend hard hat-compatible dual-ear headsets or earbuds with Noise Reduction Ratings (NRR) of 18 or greater. The higher the rating, the more protection they will provide. Remember, however, that just as important as the rating is ensuring the headphones or earbuds fit properly to provide the stated level of hearing protection.  

RELATED: Learn About NRR-Compliant Headsets

Also consider which microphone you’ll need in high-noise environments. You’ll likely want a noise-canceling microphone to help reduce ambient background noises.

Hard Hat Integration

Personal protective equipment (PPE) like hard hats are required in many industrial settings. If that’s you, you’ll want to look for a system with multiple configuration options, including dual-ear or single-ear headphones that can clip on or fit comfortably under a hard hat. Hard hat communication systems can also be configured with lightweight earbuds. 

In addition to versatile one-size-fits-all headset options, you’ll want to look for a wireless system that doesn’t require additional equipment to be attached to the hard hat for the system to work properly. While adding a few ounces here or there might not seem like a lot, the extra weight can cause neck strains and fatigue when worn throughout a shift. 

Recommended Hard Hat Communication System

While many communication systems can be configured to fit a hard hat, I most often recommend CrewPlex^® for industrial settings where real-time communication is a must.  We offer multiple two-way tour guide systems, but CrewPlex is the only completely wireless full duplex system designed for loud environments with hands-free operation.

The full duplex functionality works with up to 10 crew members, and there are several options for configuring the headsets with hard hats. There are also several options for hearing protection with headphones ranging from 18–23 NRR. Users can also easily mute their microphone with Crewplex’s exclusive SmartBoom technology by simply flipping the microphone boom above their hard hats.

While some hard hat-compatible headsets work well for guided tours or the occasional training session, CrewPlex is the go-to system for work crews on loud, rugged job sites. It’s completely mobile and intuitive, and requires no base station or FCC license. You simply turn it on and go.

Want to request a free demo or learn more about CrewPlex for your application? Contact our team to talk through your needs and we’ll find a solution that works within your budget.