Unsure what kind of safety helmet you need? What helmets comply with what standard? Where to start? At ZERO, want to make sure staying compliant is second nature, especially when it comes to premium protection that is keeping your head safe. There’s a lot to know and a lot to pay attention to when it comes to safety helmets– so we’ve done the research for you.
EN 12492, EN 397, AS/NZS 1801, and ANSI Z89 are standards that specify requirements for different types of protective headgear used in various industries and activities. While they all focus on head protection, there are key differences between these standards in terms of their geographical applicability, performance criteria, and specific requirements. Let's explore each standard in more detail:
ANSI Z89: ANSI Z89 is an American National Standard that establishes requirements for industrial head protection. It is divided into two classes: Class G (general) helmets and Class E (electrical) helmets. ANSI Z89 helmets must meet criteria for impact resistance, penetration resistance, electrical insulation, flammability, and water absorption. They are commonly used in industries such as construction, utilities, and oil and gas.
ANSI Z89.1 requires four performance tests that must be met in order to assign a safety helmet type and class, which are:
Safety Helmet Types: There are two types of protective safety helmets under this classification system that refer to impact/penetration protection:
Type 1: Designed to reduce the force of impact resulting from a blow to the top of the head
Type 2: Designed to reduce the force of impact resulting from a blow to the top, front, back, and sides of the head
Safety Helmet Classes: To improve comprehension and usefulness, there are electrical-protective classifications for helmets as follows:
Class G – General Helmet: Designed to reduce exposure to low voltage conductors, proof tested at 2200V
Class E – Electrical Helmet: Designed to reduce exposure to high voltage conductors, proof tested at 20,000V
Class C – Conductive Helmet: Not intended to provide protection against contact with electrical conductors
Basic temperature applications from -18°C (0°F) to 49°C (120°F) – No special marking on the helmet
Low-temperature applications down to -30°C (-22°F) – Labeling on the helmet “LT”
High-temperature applications up to 60°C (140°F) – Labeling on the helmet “HT”
Additionally, all safety helmets must feature a hard-outer shell and a lining that absorbs shock and incorporates a headband. Straps should suspend from the shell about 1-1¼ inches.
It is important to know that all safety helmets that adhere to ANSI/ISEA standards should be permanently marked with the manufacturer, the date of manufacture, ANSI designation, the Type and Class designation, and the head size range on the inside of the helmet shell. If your current safety helmet label is missing or is no longer legible, it is recommended that you replace your safety helmet as soon as possible.
This European standard applies to mountaineering helmets and sets out requirements for shock absorption, penetration resistance, retention system strength, field of vision, and chin strap strength. It is specifically designed for head protection in mountaineering, climbing, and related activities. EN 12492 helmets are tested to withstand the specific hazards associated with these activities, such as impacts from falling objects and rocks. Requirements include:
The updated EN 397:2025 standard defines the essential safety requirements and test methods for industrial safety helmets, offering protection in environments where there is a risk of falling objects, slips, trips or falls of a person from the same level or one above and loss of control of machinery.
To better address the range of industrial risks, EN 397:2025 introduces two helmet classifications:
Type 1 helmets are designed to protect against on-crown vertical impacts (falling objects).
Type 2 helmets provide extended protection, including off-crown impacts (front, side, and rear), and must meet additional criteria for high-energy shock absorption (98 J impact test). This marks a major evolution in the standard by aligning more closely with the performance levels seen in mountaineering helmets under EN 12492.
By doing so, EN 397:2025 bridges a long-standing gap between general-purpose industrial helmets and specialist climbing-style helmets. It adopts key principles from EN 12492, such as multi-directional impact protection and increased retention system performance, while tailoring them to the industrial setting. Importantly, however, EN 397 remains focused on helmets for occupational use—not for recreational climbing.
The standard also outlines provisions for attachment points and compatibility with accessories such as earmuffs, visors, lamp brackets, and chin straps, ensuring these do not compromise the helmet’s protective performance.
EN 397:2025 represents a significant step forward in industrial head protection, introducing a more nuanced classification system and aligning more closely with modern expectations for both safety and versatility in demanding environments.
The revised AS/NZS 1801:2024 standard sets out the safety requirements for occupational protective helmets used in a wide range of industrial environments across Australia and New Zealand. It applies to helmets used in construction, mining, forestry, shipbuilding, and maintenance work—anywhere there is a risk of head injury.
Typical hazards addressed by the standard include:
Falling or flying objects
Slips, trips, and falls—including from the same level or low heights
Accidental contact with machinery or uncontrolled tool movement
This 2024 edition introduces an expanded classification system that better reflects modern safety needs, particularly for tasks involving low-height work and dynamic movement. The four classifications are:
Type 1: General-purpose helmets for industrial use, offering vertical impact protection.
Type 4: Newly introduced in this version, enhanced helmets that incorporate a retention system and energy attenuation liner. Type 4 is specifically intended to manage the additional risks of slips, trips, or controlled falls from low heights (up to one metre)—a direct response to the growing need for better protection in fall-prone work.
Standard covers insulating helmets aimed at use on low voltage installations, which must provide protection against electric shocks and prevention of dangerous electric current passing through the head. Requirements include:
Standard covers high performance industrial helmets, which must provide protection against falling objects and lateral impact along with the resulting damage to the brain, skull, and neck. Requirements include:
While these standards differ in certain aspects, they all aim to provide adequate head protection in their respective applications. When selecting a helmet, it is important to consider the specific industry requirements and hazards involved to ensure compliance with the appropriate standard. Additionally, it is crucial to follow the manufacturer's instructions and replace helmets after any significant impact or when they no longer meet the required standards.