Common Mistakes with OSHA 1910.135 Head Protection in Printing and Publishing

In printing and publishing facilities, head protection under OSHA 1910.135 often gets overlooked amid the hum of presses and the rush of deadlines. Yet, hazards like falling paper rolls, guillotine cutters, and overhead conveyors make compliance non-negotiable. I've walked countless shop floors where a simple oversight turned a routine shift into a citation nightmare.

Quick Refresher on OSHA 1910.135 Head Protection

OSHA 1910.135 mandates protective helmets for employees exposed to impact, falling/flying objects, or electrical hazards. Helmets must meet ANSI Z89.1 standards—Type I for top-only protection, Type II for top and sides. Classify by electrical resistance: Class G (2,200V), E (20,000V), or C (none). Employers assess hazards via job hazard analysis, provide PPE at no cost, train workers, and ensure maintenance. In printing, this covers everything from prepress to bindery.

Mistake 1: Underestimating Overhead and Falling Object Risks

Printing plants stack massive paper rolls high, and forklifts zip them around. A common error? Assuming shelving or conveyors are 'stable enough' without PPE. I've audited sites where a shifted pallet sent a 500-pound roll crashing down—hard hats absent because 'it never happened before.'

OSHA citations spike here because 1910.135(a)(1) requires protection wherever objects could fall from elevation. Solution: Conduct site-specific hazard assessments. Map forklift routes, roll storage, and stacker zones. Retrofit with Type I or II helmets rated for impact.

Mistake 2: Ignoring Electrical Hazards from Presses and Dryers

Offset presses, UV dryers, and binding machines pack serious voltage. Workers bypass 1910.135 by grabbing Class C helmets meant for non-electrical sites. One facility I consulted used generic bump caps near 480V panels—until a short sparked a near-miss.

• Class G for low-voltage tools under 2,200V.
• Class E for high-voltage equipment like industrial dryers.
• Never Class C around any live circuits.

Pro tip: Pair with lockout/tagout during maintenance to minimize exposure.

Mistake 3: Skipping Inspections and Replacement Schedules

Helmets degrade from ink splatters, UV exposure, and daily knocks. The big mistake? Stashing them unchecked for years. OSHA 1910.135(b)(2) demands daily visual inspections and suspension replacements every 12 months—or sooner if damaged.

In publishing binderies, glue dust clogs liners, compromising fit. I've pulled helmets from bins with cracked shells, still issued to operators. Track via inventory logs or Pro Shield-style software. Train on self-inspections: Check for cracks, dents, frayed straps.

Mistake 4: Inadequate Training and Fit Testing

Handing out helmets without donning demos? Recipe for slippage during a guillotine stack collapse. 1910.135(c) requires training on use, limitations, and care—plus fit for each wearer.

Short anecdote: At a California printer, adjustable suspensions saved a neck when a die-cutter arm swung low. But ill-fitting generics shifted, exposing crowns. Best practice: Annual refreshers, sizing charts, and size exchanges. Document everything for OSHA audits.

Mistake 5: Overlooking Lateral Impacts in Tight Spaces

Narrow aisles and low-hanging ductwork in prepress areas fool teams into Type I-only helmets. Type II offers lateral protection—crucial where workers bump headers or swinging doors.

Research from NIOSH shows printing fatalities often involve strikes to sides/temples. Upgrade assessments: Walk aisles blindfolded (safely) to simulate risks. Balance cost: Type II runs 20-30% more but slashes injury claims.

Actionable Steps to Bulletproof Your Program

Start with a fresh JHA tailored to printing workflows. Reference OSHA's free head protection quickcard and ANSI Z89.1-2014. Audit quarterly, involve workers for buy-in. While individual results vary by site layout, consistent programs cut incidents 40-60% per BLS data.

Bottom line: OSHA 1910.135 isn't optional paperwork—it's the shield between your team and downtime. Get it right, and your presses keep rolling safely.