How to Choose a Working-at-Height Helmet?

Working at height is one of the highest-risk activity categories in occupational safety. Selecting head protection equipment for these environments requires far more attention and technical knowledge than choosing a standard helmet. While many users assume that any helmet on hand is sufficient for working at height, this misconception paves the way for serious workplace accidents.

In this article, we’ll cover in detail the difference between a working-at-height helmet and standard helmets, the technical criteria to consider when choosing the right product, and the relevant international standards.

The Difference Between a Working-at-Height Helmet and a Standard Helmet

Standard industrial helmets are primarily designed to provide impact protection against objects falling from above. However, the risk profile in working-at-height environments is much more complex:

• The worker themselves may fall, causing the helmet to strike the ground or structural elements.
• Impacts may come from the side or at an angle.
• If the helmet is not secured with a chin strap, it may come off the head during a fall.

For this reason, working-at-height helmets must meet not only the EN 397 standard but also the EN 12492 standard. EN 12492, developed for mountaineering and working at height, covers additional criteria such as lateral impact resistance, chin strap strength, and the helmet’s retention performance on the head.

Core Standards

EN 397 — Industrial Safety Helmet

This is the mandatory baseline standard for general industrial use. It covers the following tests:

• Top-point impact absorption test (5 kg weight, 1 meter drop height)
• Penetration resistance test
• Forehead rigidity test
• Flame resistance

Optional tests under EN 397 include electrical insulation (440V), low-temperature resistance (-20°C or -30°C), and high-temperature resistance (+150°C).

EN 12492 — Mountaineering and Working-at-Height Helmets

This standard adds extra safety criteria for working-at-height scenarios:

• Lateral impact test: Measures the helmet’s resistance to impacts from the right and left sides.
• Chin strap strength:
  • Breaking strength: The strap and its attachment point must withstand a force greater than 500 N (approximately 50 kgf) without breaking.
  • Elongation limits: The strap may stretch or elongate by a maximum of 25 mm under load, but must not break.
  • Width: Under a load of 250 N, the minimum width of the strap in contact with the chin must be at least 15 mm to ensure user comfort.

Safety philosophy (EN 12492 vs. EN 397):
Unlike EN 397 — where industrial helmet straps are designed to release at 150 N–250 N to prevent choking — EN 12492 straps are designed to hold firm. This is critical for preventing the helmet from rolling off during a fall while climbing or during rope access work.

• Retention system test: Evaluates the adequacy of the retention system in keeping the helmet on the head during a fall.

ANSI/ISEA Z89.1 — American Standard

This is important for companies operating in or exporting to North America. It defines two types: Type I (top protection only) and Type II (includes lateral protection). Type II is recommended for working at height.

6 Critical Criteria for Choosing a Working-at-Height Helmet

1. Chin Strap — An Indispensable Safety Element
A chin strap is mandatory for working-at-height helmets. The helmet must not come off the head during a fall. The strap must be tested to the EN 12492 standard. Make sure it has a locking, adjustable design; fixed-length straps cannot provide adequate fit.

2. Lateral Impact Protection
A standard EN 397 helmet is only tested against impacts from the top. When working at height, the head can strike structural elements, scaffolding pipes, or the ground from the side. For this reason, a helmet compliant with EN 12492 or ANSI Type II should be chosen.

3. Ventilation Holes — Evaluate Carefully
Workers in hot environments generally prefer ventilated helmets. However, it’s important to know that helmets with ventilation holes cannot undergo electrical insulation testing. In working-at-height environments with electrical risk, a non-ventilated, closed-shell helmet should be used.

4. Accessory Compatibility
Working-at-height environments often require additional equipment:

• Ear protection adapter: For noisy construction or industrial environments
• Face shield/visor: Against dust, debris, or chemical splash risk
• Headlamp mount: For nighttime or confined-space work
• Sun visor: For outdoor work

Verify from the manufacturer’s documentation that the helmet you choose is compatible with these accessories.

5. Weight and Ergonomics
For prolonged working at height, helmet weight can lead to neck fatigue. Modern working-at-height helmets are manufactured using high-strength ABS or HDPE material, weighing under 400 grams. An adjustable, non-sweating harness system is also critical for comfort.

6. Service Life and Storage Conditions
A helmet’s service life depends on the expiration date set by the manufacturer and the working conditions. As a general rule:

• Maximum 5 years from first use (or per manufacturer instructions)
• A helmet that has taken an impact must be taken out of service immediately
• Direct sunlight, extreme heat, or chemical exposure shortens the lifespan
• Do not use the helmet for driving nails or writing on it, as this can compromise its structural integrity

BBU® Safety SP-9000 — Designed for Working at Height

The BBU® Safety SP-9000 is an industrial helmet developed to meet working-at-height requirements. With its high-strength ABS shell structure, adjustable chin strap, and accessory-compatible design, it is used with confidence in the construction, energy, and petrochemical sectors.

You can find detailed technical information and certification documents for the product on our product page.

Conclusion

Choosing a working-at-height helmet is not just an equipment decision — it is also a legal obligation and a critical safety choice that directly affects workers’ lives. EN 12492 compliance, a mandatory chin strap, and lateral impact protection — these three criteria form the core framework for choosing the right product.