How to Choose the Best Head Protection in 2025
BY AsphaltPro Staff
Hard hats have been worn since their invention in the early 1900s, with regulations requiring their use in the U.S. since the 1960s. Although the concept of head protection remains the same, the variety of solutions and our industry’s collective safety knowledge have grown.
To better understand the state of head protection, J. J. Keller & Associates, Inc., a provider of safety and compliance solutions, and the International Safety Equipment Association (ISEA) conducted a study on head protection practices and challenges. Its results were released in a report titled “A Turning Point for Head Protection.”
“The first step towards achieving this goal is to understand the challenges and usage patterns of safety professionals and head protection users,” said Bob Larsen, vice president of Research & Development with J. J. Keller. “We believe that the findings of this study will inspire meaningful discussions among regulators, safety professionals and industry experts, and ultimately contribute to enhanced worker safety and well-being.”
Let’s take a look at how to apply the study’s key findings to better protect your employees.
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1) Understand the Terminology
Do you know the difference between hard hats and safety helmets, between Type I and Type II, between ANSI/ISEA Z89.1 and EN 397? While the variety of solutions illustrate important improvements in safety, this can also create confusion.
Hard hats are rigid protective helmets designed to shield the head from falling objects and impacts, while helmets provide enhanced protection against impacts, penetration and electrical hazards. Type I protects against vertical impacts while Type II offers protection from both vertical and lateral impacts.
ANSI/ISEA Z89.1 is a standard primarily used in the U.S. and focuses on industrial hard hats and helmets for a wide range of construction and general industry applications, while EN 397 is the European standard for industrial helmets.
79% of respondents know the difference between hard hats and helmets
61% know the difference between Type I and Type II
58% know the difference between ANSI/ISEA Z89.1 and EN 12492
2) Choose the Right Protection
“While the growing variety of head protection options provides greater choice, it has also introduced some confusion for safety professionals and workers,” said Cam Mackey, president and CEO of ISEA. Nine out of 10 respondents said they find it challenging to select and implement head protection.
Of the 20% of respondents who reported an employee head injury within the past year, more than half of all injuries occurred when the employee was wearing head protection, citing the wrong protection being worn for the hazard involved and improper fit as the reasons.
The study reminds us that you can’t simply look at a piece of head protection and know the level of protection it offers, recommending to read the label to know if it’s best suited for the job at hand. “Distributors, suppliers, industry associations and third-party experts and consultants can all offer valuable information and support,” said Ray Chishti, senior EHS editor at J. J. Keller.
Chishti reminds us that head protection is not a “one size fits all” approach. “Instead, it’s important for employers to conduct a job hazard analysis and/or a personal protective equipment (PPE) assessment to determine which style of head protection is best for their workers.”
3) Get Workers to Wear Them
In less than half of reported head injuries, the employee wasn’t wearing head protection.
On average, the study reports that safety professionals believe employees are wearing head protection correctly 75% of the time. In fact, only 15% of respondents said they thought head protection was being worn correctly 100% of the time.
“We give them the PPE, but I cannot stand there every day and force them to put it on,” reported one respondent. “Employees at times feel that where they are working hard hats are not necessarily needed,” reported another.
Finding head protection that’s comfortable for all workers and fits employees properly has been a challenge for safety managers, despite the variety of head protection options. “Effective protection requires wearing protective headgear correctly,” said Robin Marth, J. J. Keller EHS editor. “It must be worn appropriately, fit comfortably and be adjusted to the wearer’s head size and shape.”
“Workers complain about [head protection] being hot,” reported one respondent, and they are not alone. “Due to the hot climate, employees take off the hard hats to feel more comfortable,” said another. In fact, when respondents were asked about future innovations for head protection, 47% reported a self-cooling feature to be “very valuable.” Better impact and rotational protection followed close behind, followed by UV protection, built-in hearing protection and ambient air quality monitoring for silica dust.
4) Take Care of Your PPE
According to the study, only 54% of safety managers train workers how to maintain their head protection. The study reminds us that headgear should be inspected every day for cracks (even hairline cracks), dents and wear. Any head protection that’s cracked or looks chalky or dull should be discarded.
You should also check the condition of the suspension system and look for torn cradle straps, broken sewing lines, loose rivets, defective lugs and other defects, repairing any issues or replacing the headgear.
The study also stresses the importance of washing head protection, especially the sweatbands and cradles, on a monthly basis with warm, soapy water and rinsing thoroughly. Sweatbands should be replaced, if needed.
You should also avoid painting or using stickers on your headgear, the study said, adding that paint contains solvents that may affect headgear and stickers can obscure cracks and damage. “OSHA allows stickers only if the manufacturer approves or if the employer proves the adhesive does not impact helmet reliability,” says the study.
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Conclusion
“A head injury not only can impair an employee for life, but it can also be fatal,” Marth said, adding that in 2021-2022 nearly 96,000 private sector workers nationwide experienced an occupational head injury resulting in days away from work, job restriction or transfer. “The use of PPE… is essential in preventing head-related injuries.”
With the data from this study, J. J. Keller and ISEA “hope to inspire discussion that will further clarify effective head protection practices to keep workers safe and at home with their loved ones at the end of every shift,” Larsen said. “A critical first step toward that end is discovering what safety professionals and those who use head protection understand, where confusion lies, how they are using head protection and what challenges they face.”