When it comes to workplace safety, not all helmets are created equal. Choosing the wrong helmet class for the job isn’t just a compliance slip — it can be a $80,000 mistake.

Electrical crews who should be in Class E helmets (rated up to 20,000 volts ⚡) sometimes end up wearing Class G helmets designed only for 2,200 volts. On the surface, it may look like “a helmet is a helmet,” but the consequences of that mismatch can be catastrophic — from severe electrical injuries to costly OSHA fines and staggering medical bills.

And it’s not just about electricity. Foundries, mines, and confined spaces all demand specialty helmets that go beyond standard protection. Failing to match the helmet to the hazard is like sending a worker into a storm with the wrong umbrella: it won’t hold when it’s needed most.

This blog breaks down the differences between Class E, Class G, and specialty helmets, highlights a real-world case where improper protection led to serious injury, and explains why the right helmet is one of the smartest investments you can make — for both your workforce and your bottom line.

Class E: The 20,000-Volt Shield

Utility and electrical workers face unique risks that require Class E helmets, tested to withstand up to 20,000 volts. Anything less leaves crews exposed to fatal arc flash injuries and electrical burns. Wearing a Class G helmet in these environments is a deadly mismatch.

Class G: The 2,200-Volt Standard

For construction sites, Class G helmets are the norm. They’re tested up to 2,200 volts, providing reliable protection against falling objects and limited electrical exposure. But they’re not enough when voltage hazards climb higher.

Specialty Helmets: Extreme Jobs, Extreme Protection

Foundries, mining operations, and confined spaces require more than standard protection. Specialty helmets provide resistance to heat, molten materials, chemicals, or impact extremes. Using a standard hard hat in these environments is an accident waiting to happen.

Real Case: When Helmets Fail

In a 2016 Miami incident, scaffolding collapsed on a high-rise job, sending debris raining down. One worker suffered a serious head injury, even though helmets were in use. OSHA noted that proper hazard anticipation and correctly rated equipment could have reduced severity. (OSHA report)

Another 2024 study found that a worker still suffered a severe concussion despite wearing a standard helmet — because the helmet was not rated for the impact forces involved. Helmets are not all equal: when the hazard exceeds the rating, the results can be devastating.

$30 vs. $80,000 — The Real ROI of Helmets

• $30 helmet = daily protection, pennies per day
• $80,000 injury = medical bills, downtime, insurance claims, fines

When managers think about PPE as an expense, they miss the bigger picture: it’s a high-return investment that protects both people and budgets.

Here’s what you need to remember:

• Class E = 20,000 volts (electrical crews)

• Class G = 2,200 volts (construction)

• Specialty helmets = extreme environments

• Real-world incidents prove why proper ratings matter

• The right helmet protects lives and bottom lines

At Advanced Safety & Industrial Supply, we help safety leaders choose the right helmets for their workforce, ensuring compliance, lowering risk, and saving money.

Contact us today to strengthen your head protection program.