2025: A Year of Head Protection Changes

This year sees two key safety developments: the new bump cap standard ANSI/ISEA 100-2024 and the ANSI/ISEA Z89.1 revision.

• By Isabelle Dupuis
• Apr 16, 2025

Head injuries are one of the most frequently reported recordable injuries across numerous industries. Contusions, lacerations, bruises and other head injuries caused by worker-generated impact affect thousands of workers each year, resulting in significant injury and cost. These types of head injuries are common in workplaces where spaces are tight and workers are in close proximity to equipment and accessories.

To protect workers from such injuries, many employers use a form of safety equipment known as a bump cap. Until now, however, there was no industry standard for these products in the United States.

The International Safety Equipment Association (ISEA), in conjunction with industry stakeholders, in which our team is actively involved, has developed ANSI/ISEA 100-2024, a voluntary industry consensus standard that establishes the minimum performance, testing and labeling criteria for industrial bump caps and bump cap inserts used in the workplace.

Back to Basics—What is a Bump Cap?

A bump cap is a lightweight head protection device designed to shield the head from minor bumps and scrapes, not impact from falling objects like hard hats, which is why they deserve a dedicated standard.

ANSI/ISEA 100-2024 classifies industrial bump caps into two performance levels: Level 1 and Level 2.

Both levels are intended to reduce the force of impact resulting from a worker-generated impact to the head.

Level 1 bump caps are tested for penetration at the apex and a force transmission equivalent to 7.5 J at a single point on the front and at a single point on the back of the crown.

Level 2 bump caps are tested for penetration at the apex and a force transmission equivalent to 12.5 J at two points on the front and at two points on the back of the crown.

Accessories or replacement components, when installed, shall not cause the bump cap to fail the requirements of this standard. Chin straps, although optional, must be designed to break away at a reasonably low force to prevent strangulation.

New Bump Cap Standard—ANSI/ISEA 100-2024

Until now, the only referenced standard was usually the European bump cap standard EN812. In the ISEA Head Protection Product Group, members of which researched and developed the standard, we, of course, used it as inspiration, but it has its limitations. Most notably, it doesn't address the concept of universal bump cap inserts. ANSI/ISEA 100-2024 addresses this by adding various testing and language clarity that allows for inserts to meet the standard, accommodating the diverse needs of workers in various situations.

The standard includes detailed guidance on instructions and marking, specifying that each bump cap shall be accompanied by manufacturers' instructions explaining the application(s) of use, the proper method of size adjustment and fitting (including, if applicable, reverse wearing), and guidelines for care and inspection.

"Bump caps are a vital component of comprehensive workplace head protection," said ISEA President & CEO Cam Mackey. "However, ANSI/ISEA 100-2024 is not a replacement for products covered by ANSI/ISEA Z89.1, which provide an entirely different level of protection for a variety of similar and different hazards."

It's vital to note that the use of protective bump caps should never be viewed as a substitute for good safety practices and engineering controls.

• Bump caps are not intended to provide protection from hazards caused by falling or moving objects.
• They are designed to reduce the amount of force transmitted to the wearer from worker-generated impacts to objects, but they cannot provide complete head protection from severe impact and penetration.
• Moreover, alterations, attachments, or additions of accessories may affect the performance of the bump cap.
• Products covered under this standard that are not marked as FR, have not been tested for Flame Resistance, and may not provide protection when exposed to high heat or open flames.

Bump caps are particularly useful in environments where hard hats might be overkill, but the risk of head injuries still exists.

A few examples of situations where wearing a bump cap is appropriate might include:

• Mechanics working under vehicles or in narrow spaces, or automotive assembly lines
• Manufacturing workers exposed to low-hanging machinery or shelves.
• Aviation maintenance staff working within aircraft holds
• Utilities service employees, such as appliance technicians
• Food processing workers 

How to Choose the Right Bump Cap?

Selecting the right bump cap under the new standard involves considering several factors:

• Worksite-Specific Requirements—Short brims to improve visibility in tight spaces)
• Comfort and Fit—Padded foam, venting, and adjustable sizing are used to increase user acceptance. Levels 1 and 2 determine the type of risk, the effect, and the level of protection needed.
• Universal Inserts—For workers already wearing uniform caps, inserts are a practical way to incorporate head protection without requiring a separate hat.

Compare your options and select the optimal equipment without compromising safety for your situation.

The introduction of this new Standard marks a major advancement in workplace safety, providing manufacturers and safety professionals with a benchmark for reliable, comfortable, and effective head protection.

Safety managers have now to review and update their head protection protocols and consider where bump caps make sense. 

What's to Come for ANSI/ISEA Z89.1 in 2025?

The ANSI/ISEA Z89.1 standard for industrial head protection has undergone continuous innovation since its introduction in 1969, adapting to new materials, construction techniques, and evolving workplace hazards. Managed by ISEA, the leading trade association for personal protective equipment (PPE), the standard is developed and maintained through collaboration with industry experts, regulators, and end-users to ensure it remains relevant and effective.

Over the years, significant updates have refined helmet design and performance, including the introduction of Type I and Type II classifications in 1986, which differentiated between protection against top impacts and additional lateral protection. The 1997 revision introduced ventilation options and electrical insulation classifications, setting a new benchmark for safety. Subsequent updates have enhanced impact resistance, labeling requirements, and accessory compatibility to accommodate advancements in workplace safety technology.

The forthcoming 2025 revision is expected to address emerging trends. "The new revision will provide added protection for both Type I and Type II hard hats, which includes chinstrap requirement, retention system effectiveness and energy absorption on side, front, and rear," says Javier Hug, an active member of the ISEA Head Protection Product Group.

These updates reflect the industry's shift toward enhanced protection for workers in dynamic and high-risk environments. As industrial safety challenges evolve, ISEA continues to lead discussions on future enhancements, ensuring ANSI/ISEA Z89.1 remains a cornerstone of head protection standards worldwide.