The cap-style safety helmet is a form of traditional safety helmet that combines aesthetics with functional protection. It has been developed especially for outdoor personnel to provide head protection while offering a more civilian appearance. These hat-shaped helmets are primarily made of impact-absorbing and puncture-resistant materials and are widely used in various industries.

Historical Background

The use of head protection equipment in occupational safety dates back to the early 20th century. The first industrial helmets were introduced in 1919 by the E.D. Bullard Company and were referred to as the “Hard Boiled Hat.” Over time, these traditional helmets were enhanced through modern engineering. By the 2000s, cap-style helmet designs emerged. These new forms addressed aesthetic concerns, especially for personnel working in urban environments, and quickly gained popularity. Alongside visual appeal, improvements in user comfort led to the production of ergonomic, lightweight, and ventilated headgear. Legal regulations that promote the use of personal protective equipment (PPE) and increased employer awareness also contributed to the development of head protection equipment suited to diverse sectoral needs.

Materials Used in Production

Cap-style helmets are commonly manufactured from the following materials:

• ABS (Acrylonitrile Butadiene Styrene): Preferred for its high impact resistance and heat tolerance.
• HDPE (High-Density Polyethylene): Known for its lightweight structure and chemical resistance.
• Polycarbonate: Provides strong resistance against UV rays and mechanical impact.
• EVA Inner Liner: Used to enhance comfort and distribute shock.

These materials are selected with attention to both ergonomic and safety criteria. The interior typically includes adjustable suspension systems for proper fit and stability.

Areas of Use

Cap-style safety helmets are widely used in the following sectors:

• Municipal services (e.g., law enforcement, sanitation workers, technical staff)
• Energy distribution companies
• Telecommunications and infrastructure services
• Construction sites (especially by supervisors and inspectors)
• Emergency response teams (e.g., disaster and rescue operations)
• Landscaping and park maintenance operations

Due to their less conspicuous form compared to traditional helmets, they are also suitable for use in public or semi-formal social spaces.

Advantages

Compared to standard industrial helmets, cap-style helmets offer several advantages:

• Aesthetic Adaptation: Suitable for use in urban and public areas.
• Concealed Protection: Offers safety while maintaining a civilian appearance.
• Versatility: Appropriate for both formal and semi-formal settings.
• Comfort: Spacious interior and adjustable suspension ensure comfort during prolonged use.
• Seasonal Compatibility: Available in summer and winter models, including versions with thermal insulation.

Standards and Certification

Like all personal protective equipment, cap-style helmets are subject to national and international standards that ensure functional adequacy, user safety, and durability. Certification in accordance with these standards is crucial for legal and sectoral compliance.

TS EN 397+A1 – Industrial Safety Helmets

The primary standard that cap-style helmets in Türkiye must comply with is TS EN 397+A1, which is the Turkish version of the European standard EN 397. It outlines the performance requirements for helmets intended for industrial use, including:

• Impact Resistance Test: Assesses energy absorption after a 5 kg weight is dropped from 1 meter.
• Penetration Resistance: Evaluates protection against a pointed object dropped with specific force.
• Flame Resistance: Measures the material’s reaction to brief flame exposure.
• Low and High Temperature Resistance: Tests the material between -10 °C and +50 °C, with optional extensions up to -20 °C and +150 °C.
• Lateral Deformation: Evaluates resistance to compression from the sides.
• Molten Metal Splash Resistance: Essential for environments involving welding or casting operations.

Helmets that pass these tests receive EN 397 certification and are deemed compliant with occupational health and safety regulations.

EN 50365 – Electrically Insulated Helmets

For workplaces with potential exposure to electricity, compliance with EN 50365 is also required. This standard covers helmets used in low-voltage AC systems up to 1000 V and includes:

• Dielectric Test: Evaluates insulation performance under specific voltage.
• Wet Environment Insulation Test: Assesses long-term dielectric properties in humid conditions.