Head injuries are among the most common and serious workplace injuries. From 2021 to 2022, there were 195,720 head injuries reported in the US, 684 of which were fatal, according to the International Safety Equipment Association. For businesses, the financial implications are staggering. The National Safety Council reports the average cost of a workplace head injury claim is $91,844. This figure includes medical expenses, wage losses, administrative expenses and other related costs.
Beyond the monetary impact, there’s an undeniable human cost, with the trauma from such injuries potentially leading to long-term physical, emotional and psychological suffering for the affected individuals and their families. But while workplace head injuries remain a significant concern, they are largely preventable with the appropriate head protection.
OSHA GUIDELINES FOR HEAD PROTECTION
The U.S. Department of Labor and the Occupational Safety and Health Administration emphasize the importance of wearing head protection in work environments with potential falling objects, struck-by incidents, overhead electrical hazards and risks from slips, trips and falls. In such environments, OSHA’s 29 CFR 190.135 mandates employers to provide head protection that complies with the American National Standards Institute Z89.1 specifications.
This standard establishes criteria for the design, performance, testing and classification of industrial helmets to ensure adequate protection against impacts, penetration and electrical hazards in the workplace. It is a benchmark used to ensure helmets meet safety and reliability requirements. With the range of safety products available today, employers and employees can select equipment tailored to their specific job requirements, ensure compliance with OSHA standards across sectors and achieve optimal safety.
TYPES AND CLASSIFICATIONS OF HEAD PROTECTION
Choosing the appropriate head protection starts with understanding the different classifications and types recognized by OSHA:
Type I: Designed to protect against blows to the top of the head, these are the types of head protection commonly used in construction and general industrial environments.
Type II: This type of safety equipment offers protection from blows to the top, back and sides of the head, making them ideal for environments with multiple impact risks.
Class G: This classification refers to head protection designed to withstand electrical shocks up to 2,200 volts. Class G hard hats ensure safety from impact and electrical risks, making them suitable for various applications, including construction, industrial settings and other environments with electrical hazards.
Class E: This classification refers to head protection designed to provide maximum electrical protection. Typically used in environments where workers are exposed to high electrical hazards, such as utility work and electrical maintenance, these hard hats are tested to withstand exposure to high voltage conductors up to 20,000 volts (phase to ground).
Class C: These hard hats are designed for environments where there is no risk of exposure to electrical hazards. Class C hard hats are typically made from lightweight materials and offer comfort and ventilation, making them suitable for general use in construction, manufacturing and other industries where electrical safety is not a concern.
If a hard hat or safety helmet doesn’t conform to ANSI/ISEA Z89.1, you can’t be sure what type and level of protection it offers. Compliant safety helmets and hard hats are manufactured using materials such as high-density polyethylene and glass-reinforced nylon. Modern protective equipment can also incorporate advanced impact energy redistribution technologies that mitigate rotational forces during impacts. These features help distribute impact energy across the headwear to help reduce brain trauma.
HARD HATS VS. SAFETY HELMETS
While these terms are often used interchangeably, there’s a marked difference between hard hats and safety helmets. Generally made from fiberglass or plastic, hard hats are designed to protect against falling objects and other forms of debris. However, they have minimal side impact protection and often lack chin straps to hold them in place. This is why hard hats are typically worn by managers and those supervising jobsites rather than the workers themselves.
Recently, OSHA announced that the agency is replacing the traditional hard hats used by its employees during site inspections with more modern safety helmets (Type II, Class G) to enhance protection. In addition to side-impact protection and chin straps, modern safety helmets may have the option of integrated face shields or goggles to protect against projectiles, dust and chemical splashes. Others even provide built-in communication systems and hearing protection. Essentially, if workers need to occupy a hazardous space for extended periods, a safety helmet will give them better head protection.
CHOOSING THE RIGHT HEAD PROTECTION
Conducting a comprehensive hazard assessment is paramount to determining which types of head protection are best suited to protect your team from the specific risks they face. Understanding the unique hazards in different work environments and individual tasks allows you to select the protective equipment tailored to mitigate those dangers.
Consider the following factors when making your choice:
Electrical Work: Class G and Class E head protection are constructed from non-conductive materials to prevent electrical shocks. Some advanced models combine head, face and eye protection with integrated features like an arc flash face shield. Remember, vented hard hats or helmets cannot be used for tasks involving electrical work or proximity to electrical hazards, as vents allow electrical currents or arcs to reach the wearer’s head.
Toxic Gases and Chemicals: Head protection with an integrated or attachable face shield provides crucial protection against chemical splashes and sprays. There are also all-in-one NIOSH-approved helmets that offer head, eye, face and respiratory protection, which can minimize potential interference with tools, machinery and other PPE, such as fall-protection harness systems.
Working From Heights: A robust, adjustable chin strap is crucial to keeping the helmet securely on the head, even during sudden movements, falls or wind gusts. Look for a three- or four-point chin strap for optimal security.
Low-Visibility Environments: Choose brightly colored head protection with reflective markings to enhance visibility when working at night, near traffic or in low-light environments. High-visibility head protection should be marked HV on the label.
Extreme Temperatures: In high-temperature environments or tasks with potential exposure to molten materials, workers need head protection with advanced heat-resistant properties. These are marked HT on the label. There are also cooling pads, neck shades and sweatbands that can be attached to hard hats to provide additional comfort and protection against sun- and heat-related hazards.
As ISEA notes, don’t pick head protection based on how it’s marketed. Always check the labels on protective equipment to ensure it meets the specific requirements and standards necessary for user safety. Labels provide essential information about the level of protection (impact resistance, electrical insulation, chemical resistance) and often include certification marks from recognized safety organizations. This is the best way to ensure you get the proper head protection from this type of PPE.
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