HEAD PROTECTION DESIGN IS CRITICAL

There are between 150,000 and 200,000 lost time head injuries and numerous fatalities resulting from blows to the head each year. Because of the damage those injuries do, the cost is enormous in terms of both money and human suffering. Yet we find so little is known about head protection by buying decision makers and influencers.

Many head protection purchases are straight rebuys "that is what we've always used", or are the cheapest hard hat available with an ANSI label. That is based on the mistaken assumption that all hard hats with an ANSI label are alike, perform the same, and provide the same value. Companies willingly spend $200 for a pair of safety boots but balk at paying $20 for a good hard hat. Foot injuries are serious and good foot protection should be provided, but they pale in comparison to the devastation of a serious head injury.

The OSHA PPE Buying Decision Process calls for a buying decision maker to determine what type of PPE is required for the hazards of a job and then to evaluate as many brands and styles of that type of equipment as possible before selecting the most appropriate one. There are approximately eight major manufacturers of hard hats in the USA today. If you place each of their offerings side by side, a simple visual inspection will show you that they are not all alike. In fact, no two of them even look the same.

Yes, they all consist of a hard outer shell, a suspension, and some sort of headband, but the designs of those components and especially the way they work together to perform the functions of head protection are completely different. Let's begin with the design of the shell. Over the years, head protection studies have determined that a smooth crown, with no ribs, ridges or protrusions, and no openings in the shell (like mounting slots) is the optimum design for allowing the various components to work together to manage impact force.

Why a smooth crown with no openings? The physics of impact force attenuation requires a hard hat to go through sequential steps:

1. On impact, the shell flexes absorbing some force
2. The impacting object is deflected away
3. Impact energy is passed to the suspension through load bearing "points"
4. The Impact Energy Control System (suspension) stretches to attenuate force

If anything interferes with that sequence, the whole system breaks down and protection is compromised. Ribs, ridges and protrusions present the risk of an impacting object being caught and trapped in them. If that happens, the shell cannot flex and deflect the object away which causes all of the force of the impact to be concentrated in that one area of the hard hat. That can overload the suspension at that point which will cause it to breakdown.

So why then do most brands of protective caps on the market contain ribs, ridges and protrusions in their designs? The ANSI standard requires a crown impact test. If a brands Impact Energy Control System (suspension) is not adequate, the shell has to be "beefed up" with reinforcing ribs or thickened with ridges in order to pass. Designing a high performance Impact Energy Control System is technically challenging. It is much easier and less expensive to just beef up the shell. If a suppliers mission is to produce a hard hat as cheaply as possible, to sell it for the lowest price, that is the design they choose.

Those suppliers who's mission is to design a protective cap up to a performance standard instead of down to a price have embraced the optimum smooth crown design. Because there are smooth crown brands and models on the market, why take the risk, no matter how small it may or may not be, of buying models with ribs, ridges and protrusions when you don't have to? Isn't risk reduction what PPE is really all about?

The Fibre-Metal Products Company conceived, developed, perfected and introduced the smooth crown protective cap design almost 50 years ago. The brand is now produced by Honeywell Safety Products. In recent years, other brands have copied the Fibre-Metal shell design but again, when you put the two or three smooth crown brands side by side, you will see major differences in the total products and how they perform.

You cannot look at shell design without considering the Impact Energy Control System (suspension) that must work with it. The same studies that recommended a smooth crown design, also determined that an optimum Impact Energy Control System should have as many load bearing "contact points" as possible. The reason is because during normal wear, the "load" the contact points must bear is the weight of the cap. Multiple points divide the weight into smaller increments and spread it over the widest possible surface of the head for comfort. On impact, the "load" is the impact force transmitted from the shell to the Impact Energy Control System through the contact points. Again, multiple points divide the impact force into the smallest possible increments and spread it over the widest possible head area for maximum attenuation.

The original Fibre-Metal design, the design that set the standard for quality head protection and is still being produced today, is the only design that combines the optimum shell design with the optimum Impact Energy Control System design. Their 8 point, technologically advanced system contains more contact points than any other brand. Suppliers that copied the smooth crown design were not able to copy the 8 point Impact Energy Control design. So who knows how their 4 or 6 point Impact Energy Control Systems will hold up without the reinforcing ribs in their shells.? Again, all brands of protective caps on the market pass the ANSI Standards, but why incur the risks of less than an optimum design, that could fail in the real world, if you don't have to?

Often over looked are the ergonomic considerations involved with head protection. First, the cap should have a low center of gravity for balance and stability. Having the maximum number of suspension points will also help in this regard. The headband should have small increment size adjustments; should be able to be raised, lowered, and angled for individual fit and feel. It should be replaceable for sanitation and comfort purposes.

A final consideration is the condition of the head protection when it is shipped. Quality protective cap suppliers ship their products to you fully assembled, ready to wear. Suppliers in the price market take a short cut by just dropping the suspension into the box for the wearer to install. On the surface, that may not seem like much of an issue. But beneath the surface, it is a very risky practice. In order for the Impact Energy Control sequence to function, the suspension buttons or tabs must be firmly and securely seated in their pockets in the cap. That is not as simple as it looks.

If a suspension contact point button or tab is not fully engaged, the Impact Energy Control System could fail on impact. Quality head protection producers use skilled, well trained workers to install the suspensions correctly. Their quality control inspections provide a double check. Are your workers trained and skilled in assembling head protection? Does anyone double check to make sure they do it right? If not, once again, you are taking an unnecessary risk that you don't have to take.

When you are in the market for head protection, follow the OSHA recommended buying process procedure and do your due diligence to make sure you know what is available, what the differences are among what is available and what the value of those differences are. Compare all brands and models to the optimum designs and performance. Ask a lot of questions. Make sure you buy the best product for your application with the minimum risks.

PPE FOR COLD TEMPERATURES

Before long it will start to get cold in many parts of the country. Protection from the cold is a high priority with OSHA and NIOSH. Frostbite and other cold related conditions are considered recordable injuries by OSHA. As usual, engineering and administrative means are the preferred methods of limiting exposure to the cold, but specialized PPE often provides the first and last line of defense against the elements.

In addition to the hazard of direct injury from the cold, workers become sluggish, and distracted which puts them at risk for other injuries. Productivity also suffers when employees are exposed to temperature extremes. My four page article reprint, detailing the hazards of a cold working environment, is available free of charge by emailing your request to bob.ennamorato@gmail.com and using "PPE for Winter" as the subject line.

Taking time to become acclimated, limiting exposure to short intervals, and "layering" clothing to maximize warmth are all important to protect from the cold. But appropriate hand, foot and head protection are equally as important. Protective gloves, boots and shoes, insulated to protect from the cold are well know PPE devices. But what not be as well known are the protective cap winter liners, neck warmers, vests and other products equipped with pockets for warming devices.

The air activated warming packets provide warmth all shift long in most work environments. In addition to being inserted in the PPE specially designed for them, the warming packets can be dropped in boots, placed in gloves and clothing pockets for an extra margin of protection from the cold.

Now is the time to check into what PPE is available for protection from the hazards of cold weather and cold working environments. Make sure you check everything before you decide and then get it in stock before the first cold snap or snow storm. The return on your investment will be lower injury costs, higher productivity, and better morale.

PPE CONTRIBUTES TO PRODUCTIVITY

The safety benefits and lower injury costs related to quality PPE are obvious. What is not so obvious are the productivity related cost reduction and profit enhancing possibilities.

It is well documented that a confident, comfortable, well protected worker stays on the job longer and produces more with fewer rejects. How would you feel if you worked in a hazardous environment and the PPE your employer provided you all came from the lowest bidder?

PPE, like all products, is priced the way it is for a reason. It is highly unlikely you will find PPE loaded with safety and comfort features at the lowest price. It is said that the purchase price of a product reflects its true worth. A $5.00 protective cap is worth $5.00 while a $15.00 protective cap is worth three times as much. The cap requiring the higher initial investment is worth more because it is more capable of doing more things which will produce a greater return on that investment.

It begins with morale. A worker who starts his or her day, confident that they are well protected and free of the fear of injury feels good about themselves and the company and their positive attitude is reflected in their productivity. Because their higher quality PPE fits and feels better, they are not distracted or fatigued by it and they can produce more with fewer rejects.

Downtime is a leading drain on productivity. Poorly designed, ill-fitting, uncomfortable PPE results in time wasted trying to adjust it to fit better, frequent breaks, even trips to the dispensary for something to relieve a headache or other ailment. All of which contribute to downtime.

Well designed PPE, loaded with performance and comfort features that allows the wearer to adjust it for a perfect individual fit and feel, and that makes him or her feel like they will return to their families safe and sound each day, will have a positive impact on productivity. And productivity improvement drops straight to the bottom line returning any additional initial investment many times over.

LOOK BEYOND PPE STANDARDS

Knowing that the PPE you selected contains an ANSI sticker and believing it is the most appropriate for your hazards are first steps. You need to find out how it protects and what are the risks when hazards are more extreme than the ANSI tests. ANSI administers consensus performance standards for most PPE. An ANSI sticker on a product is your assurance that it has been tested to the ANSI standard and passed.

But ANSI standards only test products under laboratory conditions to hypothetical hazards designed to emulate what might happen in the work place. So you need to know exactly how any PPE you are considering works and if and how it can minimize your risk when hazards are different or more severe than lab conditions.

For example, most protective caps appear to be alike, and most if not all contain an ANSI sticker. But if you look beyond the obvious, you will see significant design and performance differences between the brands you may be considering. The optimum protective cap designs have smooth crowns and as many suspension "points" as possible to spread and manage impact force more effectively. But a lot of caps contain reinforcing ribs or ridges in the shells and have 4 or 6 point suspensions. Only the top quality head protection on the market has a smooth crown and an 8 point impact energy control system. Both designs are tested to the ANSI standard and both designs pass, but because the absolute test results are never made public, you never know if one design just sort of passed while the other passed with flying colors. You just know both passed.

The basic impact test for protective caps involves a ball being dropped squarely in the center of the cap. To pass the test the cap shell and suspension must work together to attenuate impact force to an exceptional level. The ribs and ridges in caps with that design reinforce the shell where the drop ball hits to compensate for their 4 or 6 point suspensions. But in real life, falling objects are rarely if ever smooth round balls striking precisely in the center of the cap. If the hazard is a wrench, or screw driver that hits off center, the ribs and ridges can become "catch basins" that can trap the object which concentrates force and over powers the suspension. So a design built for performance in the lab can create unforeseen hazards and increase risk in the workplace.

Because the very essence of risk management is to eliminate risk whenever possible, choosing the top quality protective cap design, with a smooth crown and 8 point impact energy control system, eliminates the risks caused by ribbed caps design and increases the likelihood that the cap will perform better in real life because of the ability of the 8 point suspension to manage impact force better. Two products, both with ANSI stickers, but with different performance functions and capabilities. There is much more than meets the eye like this with all types of PPE. As we detail the different product types, we will make the differences clear.

As part of your OSHA suggested PPE Buying Decision Process, you need to make sure you don't just settle for the minimum. Ask questions, probe deeper, find out exactly how and why the PPE you are considering works. Pay particular attention to performance features and make a determination of the products ability to reduce risk under your working conditions. Ask for samples. Put the products side-by-side and compare them. Try them out. It is a big decision and looking beyond the obvious will pay huge dividends.

ESTABLISH CHOICE CRITERIA

A lot of PPE is similar in appearance. Even the most conscientious buying decision maker has difficulty sorting it all out. What should you look for? How do you tell the difference? What is the value of the differences, if any? If you follow the OSHA guide lines, once you determine the "type" of PPE for your hazards, the next step is to learn as much as you can about what is available in that type of protection.

Trade journal advertising and Directories, the Internet, your sources of supply will all make you aware of the manufacturers of each type of PPE. Their literature will give you a general idea about the features, benefits and value of their brands, but spending the time to sit down and talk with the producers and distributors of the brands you are interested in is critical to the process.

Although different brands of PPE products may seem alike, there are significant differences in design, material, comfort and performance. Have each potential source tell you their "story". If they don't have a "story", dismiss them out of hand. If all they can offer is a "deal" or a lower purchase price, scratch them off of your list. Your PPE budget is not a savings account. It is an investment in reducing injuries and injury costs and only top performing products can produce a return on that investment.

As you listen to each "brand story", you will become aware of various features that are "must have's" and "would be nice to have" for your operation. Those things eventually become the "buying decision choice criteria" you specify. Once your choice criteria are set, instead of specifying a specific brand, you can state to your buying department that "no matter what brand it is, it MUST have this set of features, benefits and values." And don't forget to add "No substitutes" to your requisitions.

FITTING AND COMFORT ARE IMPORTANT

OSHA studies, based on Bureau of Labor Statistics Work Injury Reports, show that roughly 40% of those injured were not wearing the PPE provided to them, and the other 60% were wearing PPE that proved to be inadequate for the hazards present. The percentages vary according to the type of PPE in question, but the "40/60" ratio is a good representation for eye, face, head and hand injuries.

Why don't employees wear PPE that is provided free of charge by their employer? There is some resistance because they think it is not needed, or it isn't "macho", to wear it, or they don't like the way it looks, but most of the resistance is because the worker doesn't like the way it feels (it is too hot, too heavy) and it keeps them from doing their jobs productively.

Most complaints about "feel" are because the PPE was not or could not be adjusted properly for an individual fit and feel. Either the equipment did not contain enough adjustment features, or the buyer was not aware of them and the employees were not trained properly in how to make the protective device fit properly. Once again, trying to save a couple of dollars on the purchase price by selecting cheap ill-fitting PPE that can not be adjusted for a comfortable fit, is a big mistake. The most expensive PPE is that which is not worn. That is something all buying decision makers need to keep in mind and comfort and fitting capabilities should be right after protective capabilities among choice criteria.

The buying decision process also contributes to the 60% of PPE that proved to be inadequate for the hazards. When an accident and injury occurs, there is usually an in depth investigation of what the injured worker was doing, his or her working conditions, the hazards present, the PPE worn in terms of its performance, but no one ever looks at why and how that particular PPE device was selected in the first place. Did the buying decision makers works through the OSHA suggested selection process? Or did they go for a straight re buy (what we always used), or they bought something that was on "sale" (to save a few bucks), or they bought whatever had the lowest purchase price (thinking they were reducing cost) or did they just not do the due diligence to make sure they selected the most appropriate PPE for the hazards present?

You know, the OSHA Appendix to its revised PPE Rule, clearly states that "price shall not be the determining factor" in selecting PPE for an identified hazard. But unfortunately it so often is in todays PPE buying decision process. Comfort, fit, and making sure they are "must haves" in a PPE buying decision process, are important factors in any successful PPE Program.

PURCHASE PRICE vs COST AND ROI

Not knowing the differences among what is available usually leads to purchasing what has the cheapest purchase price. That stems from the mindset that PPE is a regulatory expense that should be minimized. But the truth is, PPE should be an investment in reducing costs with an ROI on a par with any other cost cutting measures an employer may be pursuing.

Lost time injuries cost close to $50,000 each today. Non-lost times injuries close to $5,000 and even First Aid cases about $500 each. Investing in quality PPE sufficient to reduce any of those costs even marginally will return the purchase price many times over. Downtime is another major cost. Comfortable, well fitting PPE, helps workers stay on the job longer and produce more. Again, spending a few dollars for design, comfort and fitting features will be returned many times over. An investment in quality PPE also helps to reduce Workers Comp insurance premiums and all of the costs involved with it.

Yes, every company wants to reduce costs. But with PPE it is important to recognize and understand which costs are the target. Do you want to try to save a couple of bucks on the purchase price of a protective cap for example, or do you want to invest that extra couple of bucks in a protective cap that is more likely to prevent or reduce an injury, more likely to be worn because it fits properly, more likely to help the wearer be more productive because it is more comfortable and that reduces the cost of Workers Comp insurance?