Considerations for Choosing Head Protection: OSHA Compliance, Hazard Assessments, and Technology Advancements

What to know about head protection types, classes, accessories, and more.

• By Dennis Capizzi
• Sep 10, 2024

With so many standards and industry regulations surrounding PPE for construction, and various head protection options such as Type I vs. Type II and Classes including Class G, E and C to choose from, it can be challenging to know which head protection solution is right for your specific job site or application. The first step in selecting proper head protection is to conduct a hazard assessment to understand the unique risks associated with your job site; and the recently updated Occupational Safety and Health Administration (OSHA) “Head Protection: Safety Helmets in the Workplace” Safety and Health Information Bulletin (SHIB) also raises many important points about proper head protection selection to consider.

Why Proper Head Protection Is Important for Construction Workers

Year over year, industrial workers in the United States continue to experience on-the-job injuries and fatalities related to falling objects and equipment as well as slips, trips and falls. Between 2021 and 2022, some of the top causes of days away from work included “slips, trips, and falls” and “contact with objects and equipment.”

One of the most serious types of injuries that can result from falling objects and equipment or slips, trips, and falls is Traumatic Brain Injury (TBI). A commonly known form of a TBI is a concussion. This is especially important for construction workers, as according to the Centers for Disease Control and Prevention (CDC), the construction industry has the greatest number of both fatal and nonfatal work-related TBI among U.S. workplaces.

This makes understanding construction job site hazards tied to falling objects and equipment or slips, trips, and falls, as well as differences in Type I and Type II impact protection even more important for workers in this industry. OSHA’s “Head Protection: Safety Helmets in the Workplace” SHIB states that “Proper head protection is crucial in work environments with falling objects, struck-by, overhead electrical hazards, and risks from slips, trips, and falls.”

Understanding the OHSA “Head Protection: Safety Helmets in the Workplace” SHIB

An updated version of OSHA’s “Head Protection: Safety Helmets in the Workplace” SHIB was released in April 2024, following the original release in November 2023, to help clarify some key points about head protection types, classes and considerations when selecting a solution. The OSHA SHIB states, “With a thorough understanding of the benefits and capabilities of head protection options, employers and workers can make informed decisions on selection and use.”

The SHIB states that “modern head protection—whether it’s a safety helmet or a hard hat—varies in styles and levels of protection, allowing employers and workers to choose head protection appropriate for the job.” OSHA continues, “Employers must conduct a hazard assessment at their job site and based on the workplace hazards, determine whether head protection is necessary and, if so, the most appropriate type.”

Head Protection Types and Classes Outlined in the OSHA SHIB

OSHA recognizes two Types (impact) and three Classes (electrical) of head protection. 

These include:

• Type I head protection, offering protection from impacts to the top of the head.

• Type II head protection, offering protection from impacts to the top of the head as well as lateral protection

• Class G (General) head protection, designed to help reduce exposure to low-voltage conductors and proof tested at 2,200 volts (phase to ground).

• Class E (Electrical) head protection, designed to help reduce exposure to higher voltage conductors and proof tested at 20,000 volts (phase to ground).

• Class C (Conductive) head protection, which is not intended to provide protection against contact with electrical hazards.

The SHIB also notes that accessories such as chinstraps, face shields, eye protection and hearing protection may also be considered to address specific job site and application hazards.

Considerations When Conducting a Hazard Assessment

While OSHA has determined that Type II, Class G safety helmets are the most appropriate type of head protection for its employees, OSHA recognizes that “based on their own Job Hazard Analysis, employers and workers may decide that another form of head protection is for them.”

Some important factors to keep in mind when conducting a Hazard Assessment include:

• Previous records of head injuries or near misses.

• Impact and other risks, including falling objects, hitting or bumping the head, lateral impact, electrical shock, or chemical splash.

• Job-related tasks and applications, such as working at height, confined space entry, climbing or welding.

• Environmental conditions such as electrical sources, extreme weather or high noise.

Additional factors to consider when choosing head protection may include comfort and worker compliance and your organization’s customization requirements for PPE. 

How to Select Head Protection

The OSHA SHIB includes considerations for choosing head protection for:

• Construction sites, especially those with high risks of falling objects and debris, impacts from equipment, awkward working positions, and/or slip, trip, and fall hazards.

• Oil and gas, where workers face potential exposure to chemicals and severe impacts.

• Working at height.

• Electrical work or tasks that involve proximity to electrical hazards.

• High- and low-temperature environments.

• High visibility for construction and road work.

• Specialized work environments that may require integrated face shields, hearing protection or communication devices.

These considerations are based on specific applications. Because the hazards your team faces may vary, consider whether they would benefit from a head protection solution that is different from what has been highlighted in the SHIB.

How to Inspect Head Protection

It’s important to note that head protection is intended for single-use impact protection. So it may not retain its full effectiveness after an incident. Any hard hat that has withstood an impact or penetration should be immediately removed from service and replaced.

Inspecting your head protection prior to each use and throughout the day can help ensure that its protection capabilities are not compromised, even from what may look like minor damage or a hairline crack.

OSHA outlines general inspection steps and storage guidelines in the updated SHIB:

• Inspect the outer shell for cracks, dents or other signs of damage.

• Examine the suspension system (headband and chin strap) for wear and tear.

• Check for labels and certification marks.

• Examine accessories and attachments.

• Check for proper fit.

• Refer to the manufacturer’s guidelines for recommended lifespan or guidance on when to take head protection out of service.

• Clean and dry head protection before storing.

• Maintain a record of each inspection, noting the date, any findings and actions taken.

Head Protection Innovations that Comply with the OSHA SHIB

Some of the recent innovations for hard hats and safety helmets can help address specific jobsite concerns and worker preferences. For example, hard hats featuring thermal barrier technology to redirect or block the sun’s rays can help reduce worker heat stress in sunny conditions by helping keep the inside of the hard hat cooler than those without this technology. This may be beneficial for workers at risk of seasonal heat stress in applications, such as road construction or working at height.

If TBIs resulting from contact with objects or equipment or slips, trips, and falls are a primary concern, consider additional layers of protection that are designed to help reduce rotational motion and the risk of traumatic brain injury from certain angled impacts. Rotational motion is one of the most common causes for traumatic brain injuries including concussions, the symptoms of which can range from low to high severity: headache, dizziness, memory loss and varying degrees of unconsciousness. This makes it especially important that workers continue to prioritize safe PPE usage. A hard hat or safety helmet with a layer designed to help reduce rotational motion works by allowing the helmet to move relative to the head at impact. This relative movement redirects energies and helps reduce the harmful rotational motion of the head.

Conducting a hazard assessment is an important first step in choosing the head protection solution that is right for your needs. Determining the unique risks and concerns associated with your specific job site and application can help identify whether Type I or Type II, Class G, C or E, or inclusion of additional accessories or technology features is right for your organization.

This article originally appeared in the September 2024 issue of Occupational Health & Safety.