Updated 21.01.2026.
The life expectancy of a safety helmet largely depends on the material used and the conditions in which it is worn. Sunlight, UV radiation, temperature variations and chemicals all affect how the material ages.
This article will explain how long a safety helmet lasts, which factors shorten its lifespan and provide tips on how to maintain it.
Which materials determine the life expectancy of a safety helmet?
Safety helmets are made of different plastics. The two main categories are thermoplastics and duroplastics.
Thermoplastics
- Polyethylene (PE)
- Polycarbonate (PC)
- ABS (a thermoplastic polymer)
- Polyamide (PA)
These materials contain plasticisers that provide both toughness and strength. Heat and UV radiation slowly evaporate these plasticisers, causing the material to become brittle over time.
Duroplastics
- Textile phenol
- Glass fibre/polyester
These materials are more resistant to UV radiation and heat, but damage to the surface can significantly shorten the lifespan.
For how long can I use my safety helmet?
In normal use, i.e. in daylight and temperatures between -5 and 30°C, the strength of the material decreases noticeably after 3-5 years. This is why manufacturers have maximum usage periods for each material type.
Lifetime by material type
| Type of material | Abbreviation | Service life |
|---|---|---|
| Polyethylene | PE | Max 5 years |
| ABS polymer | ABS | Max 5 years |
| Polycarbonate | PC | Max 5 years |
| Textile phenol | - | 5 and 10 years |
| Fibreglass | - | 5 and 10 years |
| Polyester | - | 5 and 10 years |
Tip: Some helmets have a UV indicator that discolours the more UV radiation the helmet has absorbed. This gives a realistic indication of actual ageing.
How do you recognise ageing or damage to your safety helmet?
Regular inspection is essential to monitor the lifespan of your safety helmet . Both the outer shell and the interior can wear out or be damaged, even if you have not felt an impact.
Check exterior
Note:
- discolouration or a dull surface
- hairline or small cracks
- deep scratches
- scale distortion
- feels brittle or dried-out
For helmets made of textile phenol or fibreglass/polyester, even slight superficial damage is a serious risk. While these materials are more resistant to UV radiation, surface damage significantly shortens their lifespan. Therefore, in practice, they should be used for 5 to 10 years, depending on the condition of the helmet.
Check the interior
The interior is just as important as the shell. Check:
- cracks in the straps
- worn or dried-out plastic components
- loose or damaged fixing points
The interior of thermoplastic helmets should always be replaced after 5 years, even if everything still looks fine.
When should you change your safety helmet?
You should replace a safety helmet immediately, regardless of age, if:
- the helmet suffers an impact
- the UV indicator is discoloured
- there is visible damage, such as cracks, deep scratches or distortion
- the interior is damaged or worn
In addition, maximum periods of use (per material type) are:
- Thermoplastic helmets (PE, PC, ABS, PA): replaced up to 5 years after date of manufacture
- Duroplast helmets (textile phenol, fibreglass/polyester): 5 to 10 years, depending on conditions of use
