Hotness, weight, fitting problems etc., have been found to be the chief causes of the unpopularity of industrial safety helmets in tropical environments in developing countries (DC). Some selected safety helmets manufactured in industrialized countries (IC) were modified to provide extra head ventilation and to reduce weight, in order to make them more acceptable to users in hot environments. The modified helmets were subjected to ergonomics evaluation both objectively and subjectively in the laboratory (in simulated tropical conditions) as well as in the field situation. There was evidence that white helmets had some advantages in comfort, viz. reduction of hotness, compared to the other colours, e.g. red, green etc., when worn in the presence of radiant heat in the laboratory. Ventilation holes provided at the top of the shell seemed to reduce the greenhouse effect within the helmet shell which therefore felt less uncomfortable than a fully covered helmet. Even with a small reduction of weight, such as 45 g in helmets weighing about 350g, the difference in weight was perceived by the wearers. In adapting helmets made in IC for use in tropical climates, head ventilation and low weight perception are important aspects in comfort which need to be considered. In addition to low cost, a harness material suitable for sweat absorption is required. Adjustability and sizing to fit 90% of the user population also needs to be considered in the design and manufacture of safety helmets for people in DC.