Background

Head injuries are one of the most frequently reported recordable injuries across numerous industries. Contusions, lacerations, bruises, and other head injuries caused by worker-generated impact affect thousands of workers each year, resulting in significant injury and cost. These types of head injuries are common in workplaces where spaces are tight, and workers are in close proximity to equipment and accessories.

According to the Bureau of Labor Statistics (BLS), head injuries account for approximately 78,000 incidents resulting in at least one day away from work each year in the private sector. (BLS reported 156,000 in the two-year period from 2021-22). Notably, only 7.2% of these injuries occur in construction, where hard hats are commonly used, while service workers and those in transportation and material moving occupations—sectors less likely to utilize hard hats or bump caps—account for 22.1% and 20.6% of head injuries, respectively.

To help prevent these injuries, many employers use a form of safety equipment known as a bump cap. Industrial bump caps serve as a category of personal protective equipment (PPE) designed to protect workers from bumps, scrapes, and cuts in environments where traditional hard hats or safety helmets may not be required or practical. However, until now, there was no industry standard for these products in the United States.

Introducing a New Standard for Industrial Bump Caps

With workplace head injuries sidelining tens of thousands of workers each year, the American National Standards Institute (ANSI) announced on January 15, 2025, the new ANSI/ISEA 100-2024 Industrial Bump Cap Standard to establish a consistent guideline for classification, test procedures, and performance requirements for bump caps, aiming to reduce injuries caused by head impacts with stationary objects and incurring lacerations or other superficial injuries.

Why was ANSI/ISEA 100-2024 Developed?

As previously mentioned, until now, there was no safety standard for bump caps in the United States despite the growing demand for the product. Bump caps protect against minor bumps and scrapes, but not from falling objects like hard hats. The new ANSI/ISEA 100-2024 bump cap standard provides clarity on protection levels while allowing workers to continue using the trusted products they rely on, with improved safety guidance. Additionally, the amount of head injuries outside of the traditional hard hat zones identified the need for a different, application-appropriate solution.

Furthermore, the new ANSI/ISEA 100-2024 standard addresses a critical gap in workplace head protection by providing manufacturers with a benchmark for developing effective bump cap solutions where one previously did not exist. The ANSI/ISEA Z89.1 standard for industrial head protection did not cover bump caps, and manufacturers often referenced the European standard, EN812, which has limitations, particularly concerning universal bump cap inserts.

What is included in the ANSI/ISEA 100-2024 standard?

The new ANSI/ISEA 100-2024 standard defines mandatory requirements for force transmission and penetration testing and classifies industrial bump caps into two performance levels: Level 1 and Level 2. Both levels are intended to reduce the force of impact resulting from a worker-generated impact to the head.
Bump caps must meet one of two performance levels:

Level 1:

• Two force transmission tests are carried out at 7.5 J – on the front and back of the crown.
• Apex penetration is tested within a 50mm radius on the crown.

Level 2:

• Four force transmission tests are carried out at 12.5 J – at two points on the front and two points on the back of the crown.
• Apex penetration is tested within a 50mm radius on the crown.

Accessories or replacement components, when installed, shall not cause the to fail the requirements of this standard. Chin straps, although optional, must be designed to breakaway at a reasonably low force to prevent strangulation.

ANSI/ISEA 100-2024 also addresses the concept of universal bump cap inserts by incorporating testing and language clarity that allows for various inserts (including bump cap inserts that can be used with different types of headwear—from baseball caps to winter hats) to meet the standard, thereby accommodating the diverse needs of workers and various work scenarios.

Requirements for detailed guidance on user instructions and product markings, specifying that each bump cap shall be accompanied by manufacturers' instructions explaining the application(s) of use, proper method of size adjustment and fitting (including, if applicable, reverse wearing), and guidelines for care and inspection are also set out in the new standard.

The standard also includes optional tests for reverse donning, impact protection at very low temperature (-22°F / -30°C), and flame resistance.

How Do Bump Caps Differ from Hard Hats?

Bump caps are a vital component of comprehensive workplace head protection. However, ANSI/ISEA 100-2024 is not a replacement for products covered by ANSI/ISEA Z89.1, which provide an entirely different level of protection for a variety of similar and different hazards. Bump caps and hard hats both fall under the category of head protection but are designed for very different applications:

• Protection Scope: Hard hats are engineered to provide protection against falling objects and high-impact forces, making them essential for construction and other heavy-duty industries. Bump caps, on the other hand, are designed to protect against minor bumps, scrapes, and cuts from stationary objects.
• Weight and Comfort: Bump caps are significantly lighter and more comfortable than hard hats, making them ideal for extended wear in low-impact environments.
• Use Case: Hard hats are mandated in environments with risks of falling objects. Bump caps fill the need for lighter protection where such risks are minimal but head injuries from stationary hazards still occur.

Is Compliance with ANSI/ISEA 100-2024 Mandatory?

ANSI/ISEA 100-2024 is a voluntary industry consensus standard that establishes the minimum performance, testing and labeling criteria for industrial bump caps and bump cap inserts used in the workplace, which are intended to protect wearers against the effects of striking their head against stationary objects and incurring lacerations or other superficial injuries.

Compliance with ANSI/ISEA 100-2024 ensures improved worker protection, consistency across industries, and legal and regulatory alignment. Head injuries can result in significant downtime, medical expenses, and discomfort. ANSI/ISEA 100-2024 helps safety managers evaluate and select bump caps confidently, knowing they meet rigorous performance criteria. Moreover, compliance with ANSI/ISEA 100-2024 demonstrates a proactive commitment to workplace safety.

Where Can I Find the ANSI/ISEA 100-2024?

A copy of ANSI/ISEA 100-2024 is available from ISEA online here.

Connect with Saf-T-Gard to Learn More

Industrial safety is our legacy going back nine decades. For an overview of our head protection products (including hard hats and bump caps), and to order for immediate shipment, please visit Head Protection.

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