Impacts to the head cause thousands of workplace injuries and many preventable fatalities every year, according to the Center for Construction Research and Training. Struck-by hazards are one of the leading causes of all occupational injuries in the construction industry. Additionally, falling objects and similar hazards are responsible for more than one-third of all job-related head incidents. As a result, it is imperative for workers to wear the appropriate head protection when required. 

OSHA standards require employers to provide workers with and ensure they wear personal protective equipment when there is a “reasonable probability” that an injury could occur and be prevented by such equipment. Unfortunately, too often these rules are ignored and dire consequences follow.

Even though PPE is only intended to be used as a supplementary form of protection when hazards can’t be controlled by other means, it is still important that workers use it. All workers should be trained on proper PPE selection, fit, use and maintenance.

Hard hats

The hard hat is the most common form of head protection. A 2023 OSHA Safety and Health Information Bulletin specified, “Proper head protection is crucial in work environments with falling objects, struck-by, overhead electrical hazards, and risks from slips, trips, and falls. Both scientific understanding of head injuries and head protection technology continues to advance ... OSHA’s head protection standards state that there can be compliance through ANSI Z89.1-2009, 2003, and 1997: published by the International Safety Equipment Association.”

Safety helmets

Technological advancement has given birth to the safety helmet. What’s the difference between a hard hat and safety helmet? Hard hats mainly provide top-down impact protection. A safety helmet has a more cutting-edge design that offers additional protective features, including side-impact protection, chin straps and better ventilation, and it can integrate auxiliary protection. Because of these additional features, safety helmets tend to provide more protection than a traditional hard hat. As a result, OSHA is pushing for employers to choose safety helmets over hard hats. 

Types, uses, fit and care 

Hard hats and safety helmets have three classifications: Class G, Class E and Class C. 

Class G, or general head protection, offers protection against electrical hazards of up to 2,200V. 

Class E, or electrical head protection, provides the greatest protection for electricians, lineworkers and wiremen. These offer protection from high-voltage shock and burns reaching 20,000V. 

Class C, or conductive head protection, is not designed to be used in electrical work. 

When selecting safety helmets and hard hats, proper fit is critical. Equipment comes in multiple sizes and with adjustable headbands. According to OSHA, there should be sufficient clearance between the shell and the suspension system for ventilation and impact distribution. They should never be able to bind, slip, fall off or irritate the skin. 

All head protection should be inspected daily and cleaned periodically with mild soap and water. When inspecting headwear, workers should check the suspension system, brim, shell and other accessories for holes, cracks, tears, perforations and exposure to heat, chemicals or radiation. If any of these conditions are observed, the PPE is unsafe for use and should be tagged and removed from service. Typically, safety helmets have a lifespan of 5 to 10 years, unless subject to impact.

Workers should never drill holes, paint or apply labels to protective headwear. Some paints, paint thinners and cleaning agents can compromise the protective quality. All forms of head protection should be replaced after an impact from a falling object and should never be stored in direct sunlight.

Finally, several measures can be taken to reduce the risk of an accident occurring. For example, when overhead work is being performed, workers should secure all tools and materials; use toe-boards, screens, guardrails and debris nets; barricade the area and post signs; and store materials in buildings under construction farther than 6 feet from hoistway/floor openings and more than 10 feet from exterior walls. Furthermore, any time objects are moved with the potential to become airborne, employees should stack and secure materials to prevent them from sliding, falling or collapsing.

Many workplace head incidents are preventable. Greater awareness of how to protect yourself and others is critical.

For more on helmets and hard hats, check out this month's Cool Tools.

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