Bump Caps

What it is

Bump caps are made for low-clearance work where a worker might hit a fixed object, such as under vehicles, in tight machinery spaces, in aircraft and in food processing. They have a thin plastic shell, often inside a fabric cap, with some padding. EN 812 is the European standard for industrial bump caps. Bump caps do not meet ANSI/ISEA Z89.1 and are not tested for falling objects or electrical contact. Under 29 CFR 1910.135, where there is a hazard from falling objects or electrical contact, employees must wear protective helmets that meet Z89.1, so a bump cap is not acceptable there.

How to identify

Most bump caps look like a baseball cap with a firm shell inside, or a small open plastic shell. The label shows "bump cap" and, in many cases, EN 812. It will not show a Z89.1 Type and Class. Some have vents, reflective trim or a short brim.

Bump cap vs hard hat

Key points

• Use a bump cap only after a hazard assessment shows no falling-object or electrical head hazard. See the PPE hazard assessment matrix.
• Do not wear a bump cap under a hard hat.
• Replace the cap if the shell cracks or after a hard impact.
• Fabric bump caps can be washed per the maker's instructions; check that the insert can be removed first.
• Bump caps come in hi-vis colors, with lights and in short-brim styles. These add-ons do not change the protection level.

Common mistakes

• Using a bump cap as a lighter substitute for a hard hat.
• Using a bump cap near energized parts.
• Ignoring overhead hazards like stacked material or cranes in areas where bump caps are worn.
• Wearing a worn insert that no longer fits.

Governing standards: EN 812 (industrial bump caps); 29 CFR 1910.135 (occupational head protection); ANSI/ISEA Z89.1 (for comparison).

Reference only. Verify against the current governing code or standard, the manufacturer's data and the project documents before use. Apps for Distributors disclaims liability arising from reliance on this reference.