In December 2023, OSHA announced that it was replacing the traditional hard hats used by its own employees with more modern safety helmets, to better protect agency staff on inspection sites. Alongside the announcement, OSHA published a Safety and Health Information Bulletin comparing the two types of head protection.
The change applies to OSHA's own staff. It did not change any OSHA standard, and employers are not required to replace hard hats with helmets. It does signal where the agency sees head protection heading, and it gives employers useful guidance for evaluating their own options.
In announcing the change, OSHA cited Bureau of Labor Statistics data showing that in 2020 head injuries accounted for nearly 6 percent of nonfatal occupational injuries involving days away from work. Almost half of those injuries occurred when workers were struck by an object or equipment, and about 20 percent were caused by slips, trips, and falls.
What OSHA's Standards Require
The head protection rules themselves are unchanged:
- General industry (29 CFR 1910.135): employers must ensure each affected employee wears protective helmets where there is a potential for injury to the head from falling objects, and protective helmets designed to reduce electrical shock hazard where employees are near exposed electrical conductors that could contact the head.
- Construction (29 CFR 1926.100): employees working in areas where there is a possible danger of head injury from impact, falling or flying objects, or electrical shock and burns must be protected by protective helmets.
- Consensus standard: head protection must meet ANSI/ISEA Z89.1 (or be shown to be equally effective). Z89.1 classifies head protection by Type (Type I for top impact, Type II for top and lateral impact) and Class (G general, E electrical, C conductive with no electrical protection).
- Hazard assessment and training (29 CFR 1910.132): the employer's PPE hazard assessment determines what head protection is needed, and employees must be trained on when it is needed, how to wear and adjust it, its limitations, and its care and maintenance.
Both traditional hard hats and safety helmets can meet these requirements, as long as they are rated for the hazards present.
Traditional Hard Hats vs. Safety Helmets
Traditional hard hats, a design dating back to the 1960s, protect the top of the head but typically offer limited side-impact protection and no chin strap. Without a strap, a hard hat can fall off if the wearer slips, trips, or falls, leaving the head unprotected. Many also lack vents and trap heat.
OSHA's Safety and Health Information Bulletin on safety helmets describes the advances in modern helmet design and materials. Helmets typically protect more of the head, include chin straps, and can offer integrated or add-on face shields or goggles. Some include built-in hearing protection or communication systems for noisy environments.
Where OSHA Recommends Safety Helmets
In its announcement, OSHA recommended safety helmets for:
- Construction sites: especially those with high risks of falling objects and debris, impacts from equipment, or slips, trips, and falls.
- Oil and gas: where workers face multiple hazards, including potential chemical exposure and severe impacts.
- Working from heights: tasks or jobs that involve working at elevation.
- Electrical work: tasks involving electrical work or proximity to electrical hazards, with a helmet rated for the electrical hazard.
- High-temperature environments: high heat or exposure to molten materials.
- Specialized work: jobs that need integrated face shields, hearing protection, or communication devices.
- Regulatory or industry requirements: wherever helmets are specified by a regulation or industry standard.
- Low-risk environments: even settings without significant overhead hazards.
How to Inspect and Care for Head Protection
Whichever type you use, inspect head protection before each use and follow the manufacturer's instructions for care, use, and storage:
- Clean and dry head protection before storing it.
- Inspect the shell and suspension for cracks, dents, or other damage, and check the headband and chin strap for wear.
- Check that labels and certification markings are present and legible.
- Check the date of manufacture against the manufacturer's recommended service life.
- Inspect accessories and attachments, and make sure they are secure and working.
- Adjust the suspension for a snug fit that is neither too loose nor too tight.
- Inspect interior padding for wear or compression, and replace parts as the manufacturer directs.
- Remove head protection from service after any significant impact, even if no damage is visible.
- Keep a record of inspections, findings, and replacements.
Training Employees on Head Protection
Head protection is part of an employer's broader PPE program. The Personal Protective Equipment Safety Training program covers OSHA's PPE standards (29 CFR 1910.132–.138), hazard assessments, the types of PPE including head protection, and maintenance. It is available in English and Spanish as streaming access, USB, DVD, or an MP4 license, and training program kits include a PowerPoint presentation, quiz, attendance log, and completion certificate. The employer adds its own hazard assessment results and site-specific requirements.
For the full picture of PPE training requirements, see our complete PPE training program guide and our overview of PPE, chemical safety, and hazard communication training requirements.