How to Choose the Right Bullard Type 2 Hard Hat for Your Jobsite

If you're reading this, you've probably seen the term “Type 2” thrown around and wondered if it's actually necessary for your crew. Or maybe your current supplier just said it's the new standard. I get it. After reviewing over 200 unique head protection specs annually for the last four years, I can tell you there's a real difference — and it matters more than most people think.

This guide is for anyone who needs to buy Bullard hard hats for industrial work, construction, or utility jobs. I'll walk you through five specific checks you can use right now to make sure you're getting the real thing, not just a box with the right logo.

Step 1: Verify the Type 2 vs. Type 1 Distinction

You'd think this is obvious, but I've seen purchase orders where someone specified “Type 2” and received a Type 1 because the vendor said they were “basically the same.” They are not.

The core difference: Type 2 hard hats pass impact tests for both top blows and lateral, front, and rear blows. Type 1 only covers the top. If your crew is working near moving vehicles, overhead loads, or in confined spaces where side impact is possible — Type 2 is non-negotiable.

Bullard's Type 2 models, like the 500R and the S62, use a specific suspension design that absorbs energy from multiple angles. If you're looking at a hard hat that looks exactly like a Type 1 but is labeled Type 2, check the inner shell molding. The suspension attachment points should be visibly reinforced. I want to say about 60% of the counterfeit or mislabeled units I've spotted had no lateral reinforcement, just a different sticker.

Step 2: Check the Shell Material and Weight Tolerance

Every Bullard Type 2 hard hat uses high-density polyethylene (HDPE) or polycarbonate, depending on the product line. What most buyers don't check is the weight tolerance spec. I've handled units that were 10% heavier than the declared weight — not a dealbreaker, but over an 8-hour shift, that extra 50 grams leads to complaints and lower compliance rates.

For Bullard specifically, look at the weight listed on the spec sheet. The S42L, for example, should be around 390–410 grams depending on the suspension type. If your shipment comes in at 450 grams or higher, something's off. One supplier tried to convince me it was 'within industry standard' — but Bullard publishes tighter tolerances for a reason.

Not ideal, but workable: some variance happens in molding. But more than 10% off the spec? Reject the batch. Learned that the hard way after a $22,000 redo on a different project because a defect ruined 8,000 units in storage conditions.

Step 3: Inspect the Accessory Slot Compatibility

This one catches a lot of people. Bullard Type 2 hard hats have accessory slots for face shields, earmuffs, welding visors, and other gear. But the slot dimensions changed slightly in 2022 for the D8 and M8 series. If you're buying a hard hat built for older accessories, your new face shields may not click in securely.

I assumed 'same specifications' meant identical results across vendors. Didn't verify. Turned out each had slightly different interpretations of 'universal slot.'

Quick check: Bring your existing accessory into the receiving area. If the bracket doesn't seat with an audible click, reject the unit. On a 500-unit order, that mismatch adds up fast — you're looking at field replacements and worker frustration, not to mention the safety gap.

Three things: accessory fit, suspension compatibility, and shell marking. In that order.

Step 4: Validate the Certification and Date of Manufacture

Bullard hard hats come with ANSI Z89.1 and CSA Z94.1 certifications clearly printed. But here's the part most people skip: the manufacture date. Hard hats have a replacement interval — typically 5 years from the date of manufacture, per Bullard's guidelines. A helmet made 3 years ago but stored in a hot warehouse has already lost some UV resistance.

If I remember correctly, Bullard prints a two-digit week and year on the shell (like “WWYY”). I'm not 100% sure, but I think I've seen some older stock without a visible date code. If there's no date, treat it as potentially expired. The cost was around $800—no, $1,400, I'm mixing it up with the other project — but the point is, non-dated helmets are a risk you shouldn't take.

What to look for:

• ANSI Z89.1 Type 2 marking clearly visible
• CSA stamp if shipping to Canada
• Manufacture date within the last 2 years for optimal shelf life
• Lot or batch number for traceability

Don't hold me to this, but I believe Bullard's lot numbers also indicate the factory — so if you're buying from a non-authorized distributor, the code can help verify authenticity.

Step 5: Evaluate the Suspension Design Against Real Jobsite Conditions

This is the step most people ignore because it's not on the spec sheet. Bullard offers multiple suspension options: the classic 6-point ratchet, the 4-point locking, and the newer CoolGuard with moisture-wicking sweatband. They all pass the impact test. But in practice, a 4-point suspension is noticeably less stable for workers who bend over repeatedly, like electricians or pipefitters.

What I mean is, if your crew spends a lot of time in tight spaces or looking up, the 6-point is safer because it keeps the shell level during lateral movement. The 4-point tends to tilt forward. On a 50,000-unit annual order, choosing the wrong suspension system generates about 12-15% more complaints and adjustment requests.

Worse than expected. A lesson learned the hard way.

One more thing: the suspension band tension. I've seen units where the band was too loose out of the box. The standard test: with the hard hat on, tilt your head forward. If the helmet moves more than an inch before the suspension catches, it needs adjustment or replacement.

Final Notes and Common Mistakes

Let me rephrase the big ones so you don't miss them:

• Don't assume “Type 2” is the same across brands. Bullard's test pass criteria are identical to the standard, but their internal tolerance is tighter. That's why they cost more. You're paying for consistency.
• Avoid buying without checking the manufacture date. An old helmet is a compromised helmet, even if unused.
• Test the accessory fit before accepting the full order. Mismatched slots are a hidden time sink.

“I'd rather spend 10 minutes explaining options than deal with mismatched expectations later.” — something I tell every new vendor.

An informed customer asks better questions and makes faster decisions. If you're still reading, you're already ahead of 80% of buyers out there. And if you want to go one step further, keep a log of rejection rates by batch. Over a few years, that data will tell you which suppliers actually follow Bullard's standards — and which are just shipping boxes.

Pricing as of January 2025. Bullard Type 2 hard hats typically cost $25–$45 per unit for the standard 500R series, excluding accessories. Prices vary by volume and distributor. Always verify current pricing and lead times with your supplier.