SAFETY

DOC. DIVISION STEEL WORKS EFF. DATE 21.01.2006

STANDARD
DOC. # SS/GEN-07 TITLE Head protection REVISION 01
DUE FOR
SHEET 1 OF 4 21.01.2009
REVISION
COMP. BY Rajesh Kumar SIGNED DATE 16.01.2006

AUTH. BY P K Singh SIGNED DATE 16.01.2006

Purpose: This standard discusses the various types of protective helmet systems presently available, their
1.0 values and limitations. It contains sufficient information to allow for the selection of proper head
protection.
2.0 Reference:
Associated Hazards: Head injury from impact, from falling or flying objects, or from electrical shock and
3.0
burns
4.0 Applicability: Inside Tata Steel Works

5.0 Responsibility: Working departments, Consultants, Contractors

6.0 Procedure: General

6.1 Employees, including Consultants and employees of contractors, working in areas where there is a
possible danger of head injury from impact, from falling or flying objects, or from electrical shock
and burns, shall be protected by protective helmets.

6.2 Drivers and staff of all outside trucks coming to Works will be barred from entering the Steel
Works without safety helmet. This is as per the circular no. CSE/64-447/2004 dt. 6.5.04 and
CSE/64-662/04 dt. 13.07.04

6.3 A protective helmet system consists of two essential parts:

6.3.1 A hard shell, which may absorb some energy of a blow by flexing or cracking, but the main
functions of which are to deflect a falling object from the skull, to stop a pointed missile from
penetrating the skull, and to transfer impact energy to the suspension system.

6.3.2 A semielastic suspension, the main functions of which are to absorb most of the kinetic energy
of a blow, and to hold the shell comfortably over the head of the wearer

6.4 Procurement

6.4.1 Helmets for the protection of employees against impact and penetration of falling and flying
objects shall meet the specifications by local requirements for impact resistance and protection.

6.4.2 Helmets for the head protection of employees exposed to high-voltage electrical shock and
burns shall meet the local “Safety Requirements for Industrial Protective Helmets for Electrical
Workers.

6.4.3 The vendor shall be required to furnish satisfactory evidence that the product meets required
specifications, as certified by a nationally recognized testing laboratory.
 SAFETY
DOC. DIVISION STEEL WORKS EFF. DATE 21.01.2006
STANDARD
DOC. # SS/GEN-07 TITLE Head protection REVISION 01
DUE FOR
SHEET 2 OF 4 21.01.2009
REVISION
COMP. BY Rajesh Kumar SIGNED DATE 16.01.2006

AUTH. BY P K Singh SIGNED DATE 16.01.2006

6.4.4 Each helmet shall be identified on the inside of the shell in letters not less than 1/8 inch high,
with name of manufacturer, the American National Standard designation and class. The
identity of the material from which it is constructed should be obtained from the vendor. Trade
names without meaning are not acceptable. In this connection, the compatibility of the material
with plant chemicals should be considered.

6.5 Selection
6.5.1 Types available
6.5.1.1 American National Standards refer to helmets as Type 1 if full brimmed or Type 2 if
brimless. Helmets are further categorized depending upon the protection afforded according
to the following tabulation:
Penetration
and impact
Limited
voltage
High
voltage
Slow
burning
Fire
resistant
Class A X X X
Class B X X X
Class D X X X

In general, Class A helmets satisfy average industrial needs; Class B helmets are intended for
electrical workers; and Class D helmets are designed for fire fighting. Class C helmets
(aluminum for example) shall not be worn because of electrical conductivity and low
resistance to puncture by missile.

6.5.1.2 Type Brimmed helmets, Type 1, are preferred because they provide better coverage from
liquid spills and better protection against side blows. Type 2 helmets have no brim but may
include a peak. They are somewhat lighter in total weight and are necessary with some
welding equipment, respiratory and body protective equipment.

6.5.1.3 Bump caps : Featherweight plastic caps without shock-absorbing suspensions have come into
use in locations where the only hazard is that of the wearer bumping his head against a sharp
or hard object. Since bump caps have very limited protective capacity against falling objects
or missiles, they must never be used where these hazards exist.
 SAFETY
DOC. DIVISION STEEL WORKS EFF. DATE 21.01.2006
STANDARD
DOC. # SS/GEN-07 TITLE Head protection REVISION 01
DUE FOR
SHEET 3 OF 4 21.01.2009
REVISION
COMP. BY Rajesh Kumar SIGNED DATE 16.01.2006

AUTH. BY P K Singh SIGNED DATE 16.01.2006

6.5.2 Components : There are many suppliers each offering a variety of protective helmets. The
following considerations, in addition to the requirements of Section 3, are important when
making a selection.

6.5.2.1 Shell : Many basic materials of construction are used for helmet shell material. Refer to
manufacturer’s literature to ensure helmets meet ANSI Z89 standards.

6.5.2.2 Suspensions

6.5.2.2.1 The design, material, and support of the cradle suspension is of extreme importance,
since this is where the greater portion of the impact shock is absorbed. All helmets
must have fixed-crown suspension, with the fixed crown giving 1-1/4 inches
minimum to 1-5/8 inches maximum clearance below the underside of the crown.
An adjustable second cradle independent of the fixed-crown suspension should be
provided for individual comfort. Woven nylon webbing is preferred. This is not only
strong and durable, but has a controllable elasticity and weave for consistent
characteristics. Some manufacturers are using molded-plastic cradle supports, claiming
advantages such as ease of cleaning, low cost replacement, etc. The value of these
plastics is questionable on the basis that some plastics, and especially polyethylene,
change elasticity with changing temperature and will harden with age, losing elasticity
and strength.

6.5.2.2.2 As much contact area with the head by the crown support cradle as practicable is
desirable. This distributes the transmitted force of a blow over a larger area than if
supported by a few narrow straps. Provisions for extra-small or extra-large sizes are
made by some manufacturers. 4.2.2.3 Four, six, or eight cradle support points are used
by various manufacturers and all are acceptable if used as designed.

6.5.2.3 Liners :Winter liners may be worn; they should be a type that holds helmet on the head when
fastened.

6.6 Use and maintenance

6.6.1 To obtain proper protection, helmets must be worn squarely on the head, not tilted to one side
nor toward the rear. The helmet band should be adjusted just tight enough to be comfortable
and to keep the helmet in position; it is not designed to take any of the force of a blow on the
helmet. Laces, if any, always should be tied securely with a square knot.

6.6.2 Cleaning : A common method of cleaning and sterilizing shells is dipping them in hot water
(approximately 140 F), containing a good detergent, for at least a minute. Shells then should
 SAFETY
DOC. DIVISION STEEL WORKS EFF. DATE 21.01.2006
STANDARD
DOC. # SS/GEN-07 TITLE Head protection REVISION 01
DUE FOR
SHEET 4 OF 4 21.01.2009
REVISION
COMP. BY Rajesh Kumar SIGNED DATE 16.01.2006

AUTH. BY P K Singh SIGNED DATE 16.01.2006

be scrubbed and rinsed in clear water (approximately 140 F). After rinsing, the shell should be
inspected carefully for any signs of damage.

6.6.3 Periodic inspection: All components, shells, suspension, headbands, sweatbands, and any
accessories should be visually inspected daily for signs of dents, cracks, penetration, or any
other damage due to impact, rough treatment, or wear that might reduce the degree of safety
originally provided. Any industrial protective helmet that requires replacement of any worn,
damaged, or defective part should be removed from service until the condition of wear or
damage has been corrected.

6.6.4 Industrial protective helmets are designed to provide optimum protection under average
conditions. Users are cautioned that the margin of safety may be reduced if unusual conditions
prevail (such as higher or lower extremes of temperature, unusually large amounts of sunlight
[ultraviolet], solvents, greases, or corrosives), or if there are signs of abuse or mutilation of the
helmet or any component.

6.7 Precautions

6.7.1 Industrial protective helmets should not be stored or carried on the rear-window shelf of an
automobile since sunlight and extreme heat may adversely affect the degree of protection. Also,
in the case of emergency stops or accidents, the helmet might become a hazardous missile.

6.7.2 Only vendor-approved attachments may be added to helmets (welding hood clips or hearing
protectors for example). Devices which secure goggle straps to the helmet shall not be used
unless provision is made for securing the helmet to the head (such as chin strap).

6.7.3 Field modification of shell or suspension is not allowed unless approved by the vendor.

6.7.4 Suspensions : No foreign objects such as packages of cigarettes, booklets, or other personal
articles shall be kept between the suspension and the shell. Tests are specified for impact
resistance, penetration resistance, flammability, water absorption, and voltage resistance. In the
voltage resistance test, Class A and Class D helmets must withstand 2,200 volts.

6.7.5 ANSI Z89.2, “Safety Requirements for Industrial Protective Helmets for Electrical Workers,
Class B,” is comparable to Z89.1 except that helmets must withstand a 20,000-volt electrical
resistance test. Copies of either ANSI standard may be obtained from American National
Standards Institute, 1430 Broadway, New York, NY 10018.

7. For more information, refer safety standard SS/ENGG-07 on “Personal Protective Equipment”.