AI cameras for PPE checks on site: hard hats and hi vis without the hype featured image
Tools, Materials & Tech

AI cameras for PPE checks on site: hard hats and hi vis without the hype

TrainAR Team 26 days ago 5 min read

AI cameras for PPE checks on site: hard hats and hi vis without the hype

Category: Tools, Materials & Tech • Niche: AI video analytics, PPE compliance, small to mid-size contractors

Contents

AI PPE detection showing hard hat and hi vis detection at a UK site gate

Quick answer

AI can reliably spot missing hard hats from standard site cameras. Hi vis is possible, but usually needs a custom model and careful testing. Treat it as a nudge for supervisors, not a robot foreman. Keep footage tight on work areas, log events for learning, and always follow the hierarchy of controls first.

What it can and can’t do today

  • Off‑the‑shelf models (for example, Amazon Rekognition’s DetectProtectiveEquipment) recognise head cover, face cover and hand cover. That means hard hats are in scope; hi vis vests and jackets are not detected by default and require a custom model. See Amazon’s PPE API notes for capabilities and limits. DetectProtectiveEquipment – Amazon Rekognition
  • Commercial systems from CCTV vendors (Hikvision, WCCTV, Clearway) add their own analytics for PPE. Evaluate them on your actual camera views, lighting and weather before you commit. Example vendor pages: Hikvision PPE Detection, WCCTV PPE Detection, Clearway PPE Detection.
  • Open‑source routes exist (YOLOv5 models) if you have a tech‑savvy partner. Useful when you want hi vis detection tuned to your jackets and conditions. Example datasets: Roboflow Hard Hat Workers, SHWD dataset.

UK rules you must meet

  • Hard hats: On almost all sites there’s a residual head‑injury risk, so head protection must be worn; Sikh workers wearing turbans are exempt under UK law. Use BS EN 397 compliant helmets. HSE overview: Construction PPE FAQ.
  • Hi vis: Where vehicles/plant operate, hi vis is expected. For general sites Class 2 is common; for road works and high‑speed roads, Class 3 is standard per Chapter 8 practice. Use garments certified to EN ISO 20471. HSE PPE overview: Using PPE at work.
  • Duties: Since April 2022, PPE duties extend to “workers” as well as employees. Provide suitable PPE free of charge and ensure use. Regulations: PPER 2022.

Design a simple, workable setup

Use cameras you already have (static, good lighting). Start in one controlled zone like the gate or a fab bay.

  • Camera feed to cloud or NVR snapshots every 1–2 seconds.
  • For hard hats: call DetectProtectiveEquipment with HEAD_COVER and a confidence threshold you test (often 85–95). Use the summary field to count “persons without required equipment.”
  • For hi vis: train a small custom model. Include yellow/orange vests, winter coats, dirty kit, back‑lit and rainy scenes. Map the result to your policy (e.g., Class 2 minimum in plant zones; Class 3 near public roads).
  • Alerts: send a WhatsApp or Teams message to the duty supervisor with a redacted crop and timestamp. Only escalate after a quick human check.
  • Records: store detections to a simple log (Google Sheet or database) with S3/Drive retention rules, e.g., 14–30 days unless there’s an incident.

Diagram: simple flow

Flow: camera to AI to alert and log

Accuracy, false alarms and bias

  • Expect misses in rain, glare, heavy shadow, mud on kit, and with hoods up.
  • Calibrate per camera: test 50–100 example clips; set thresholds to minimise false alerts during busy periods.
  • Review a weekly sample for the first month. Track false positives and negatives, and tweak zones/thresholds.
  • Keep a human in the loop for any enforcement decision to avoid unfair bias.

Privacy and data protection

  • If people are identifiable, you are running CCTV under UK GDPR. Do a DPIA, set a lawful basis (legitimate interests is common), put clear signs up, minimise what you capture, and set a short retention period. Guidance: ICO CCTV and video surveillance.
  • Avoid facial recognition. Restrict access. Blur exports shared outside the business. Keep audio off.

Costs and ROI in plain English

  • Software: Cloud AI charges per image/minute. For a trial on one camera, budget tens of pounds per month. Vendor bundles may be per‑camera per‑month.
  • Time: A tech‑friendly manager can set up a basic trial in a day. Commercial systems take longer but come with support.
  • Payback: Preventing one injury or a near miss around plant can justify the whole setup. You also gain cleaner evidence for coaching and toolbox talks.

Step-by-step: pilot on one camera

  1. Choose zone: a gate where everyone passes a fixed point.
  2. Post signage and update your induction/briefing.
  3. Capture: configure snapshots every second during working hours.
  4. Detect: run hard‑hat detection; log any “no hard hat” events.
  5. Alert: send a WhatsApp to the supervisor with the time and still image.
  6. Review weekly: check 100 frames; tune threshold; move camera if glare.
  7. Decide next zone: add hi vis detection once the hat model is stable.

What are people saying on Reddit?

FAQ

  • Is this legal on UK sites? Yes, if you follow UK GDPR rules for CCTV and keep it proportionate. See the ICO guidance linked above.

  • Will it work on night shifts? Yes, but you’ll need decent lighting and may need to train or buy models that handle IR/low‑light.

  • Can it tell Class 2 vs Class 3 hi vis? Not reliably out of the box. You’ll need a custom model trained on your garments, and even then treat it as advisory.

  • What about visitors and deliveries? Provide a proportionate induction and escort. Use wider zones for advisory alerts only.

  • Do I need new cameras? Not usually. Fixed, stable viewpoints beat fancy cameras. Start with what you have and only upgrade if the image is poor.

  • Can I run this without the cloud? Yes. Some NVRs and vendors offer on‑prem analytics. Ask about model accuracy and update paths.

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