Change ahead

In the most significant change to industrial helmet standards for 30 years, EN 397:2025 has now been published for application across the UK and Europe.

While 21^st century advancements are revolutionising the way we work – from smartphone-based safety apps and wearable tech to automated robotics and GPS-enabled asset management – the helmets designed to protect staff have remained largely unchanged since the 1990s.

EN 397 was first introduced in 1995. Primarily intended for protection against falling objects, testing focused on the crown area with a single set of requirements applicable to all helmets. The standard underwent minor updates in 2012, including changes to the headforms used for testing, but its fundamental performance requirements remained the same.

As the industry builds higher and digs deeper, the increased risk of slip, trip and fall incidents has driven a need for all-round impact protection, plus an integral chinstrap to keep the helmet secure.

In recent years EN 12492 filled the gap despite not being fully fit for purpose. As a leisure standard, it lacked key performance options necessary for safety in workplace applications. EN 397:2025 addresses a wider range of hazards – effectively eliminating applicability of the mountaineering standard by accounting for both traditional EN 397 protection and an option closer to EN 12492 performance.

Type 1 and Type 2 helmets

The new EN 397:2025 Industrial Protective Helmet standard defines two helmet types.

Type 1 helmets are intended to absorb energy from impacts in the crown area with requirements similar to EN 397:2012. A 5kg hemispherical striker is dropped to create a 49 Joule impact on top of the helmet, and the force transmitted to the test headform must remain below 5kN.

Type 2 helmets absorb energy from both on-crown and off-crown impacts. Crown shock absorption is tested at higher energy (98 Joules) while off-crown shock absorption testing is carried out at 24.5 Joules on the side, front and rear. In these tests, the transmitted force limit is 10kN.  

Chinstraps are optional for Type 1 helmets. The harness secures the helmet on the head, but a chinstrap can be added to increase stability. Testing is carried out to ensure the strap remains connected when a force of 150 Newtons is applied.

Type 2 helmets must incorporate a mandatory chinstrap to keep the helmet secure in case of a fall or repeated impacts. Strength release testing is conducted at 500 Newtons. Retention system effectiveness is also assessed by applying a sudden force at the front and rear to check that the helmet remains on the headform.

Both helmet types are assessed for penetration resistance in the crown area. As with the 2012 standard, a 3kg pointed striker is dropped from 1m within a 50mm circle centred on top of the helmet. Type 1 helmets are subjected to a single impact whereas Type 2 helmets are tested twice, and in each case the striker must not contact the headform, ensuring protection against pointed objects falling from above.  

Special application requirements

Special application requirements are optional, setting out assessment criteria for additional features applicable to Type 1 or 2 helmets.

Off-crown penetration resistance (OCP) is a new option that enables both helmet types to be tested in a wider area. The method follows the on-crown test with drop height reduced to 375mm for a lower energy impact, replicating lateral hazards.

Electrical requirements have moved to EN 50365:2023. The new electrical insulation standard excludes vented helmets, which were previously permitted subject to testing, and covers higher voltages up to 17kV.

Molten metal requirements remain unchanged. The lateral deformation option was removed after the standards committee determined that the test was not representative of a real-life risk; however Type 2 testing now assesses side impact protection.

Higher temperature conditioning still enables testing at +150°C while the lower limit has been removed, allowing helmets to be tested below -20°C without a custom technical specification.

New enhanced visibility options specify requirements for daylight and dark conditions. Electrostatic properties have also been added with performance tests and guidance for use in different ATEX zones.

With two new performance types and an expanded range of options, risk assessments will become more crucial than ever. Hazards must be carefully assessed to specify the correct helmet.  

Compatibility assessments

Attachments are clearly defined in EN 397:2025 with testing and assessment requirements.  

Non-integral additional protective functions, as the name suggests, offer another form of protection. This includes removable visors and faceshields as well as ear defenders. Whereas a helmet accessory is an attachment that offers no additional protection, for example a lamp or camera.

Specified performance tests will be carried out with attachments fitted, where it is identified that they may affect conformity of the helmet. Details of which attachments may affect conformity, and which tests they need to be mounted for, are still being discussed by the standards committee. 

There is also a new ergonomics and mobility assessment in which subjects fit and operate the helmet, along with additions and accessories, performing basic exercises to assess compatibility.

There is no rush to update your helmet. Some details are still being finalised as test houses prepare for the new requirements. Existing EN 397:2012 approvals remain valid until the CE/UKCA certificate expiry date. Dual certification may be applied during the transition, enabling compliance with the new standard and giving employers time to review risk assessments.

Under EN 397:2025, the introduction of multi-directional impact resistance, an expanded range of performance options and standardised compatibility assessments will enable more effective protection against the hazards presented in modern workplaces.