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Related Concept Videos

Design Consideration01:22

Design Consideration

508
Designing a structure involves a series of considerations, primarily the material's ultimate strength, calculated through tests that measure changes under increased force until the material reaches its breaking point or limit. The ultimate load, where the material breaks, is divided by its original cross-sectional area, resulting in the ultimate normal stress or strength. The ultimate shearing stress is another significant factor taken into account.
The factor of safety is another key...
508

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Related Experiment Video

Updated: Jan 9, 2026

A Test Bed to Examine Helmet Fit and Retention and Biomechanical Measures of Head and Neck Injury in Simulated Impact
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Development of a Fall-Specific Impact Testing Method to Evaluate Safety Helmet Performance and Injury Risk.

Susanna M Gagliardi1, Nicole E-P Stark1,2, Mark T Begonia2

  • 1Department of Biomedical Engineering and Mechanics, Virginia Tech, 325 Stanger St., Kelly Hall 120, Blacksburg, VA, 24061, USA.

Annals of Biomedical Engineering
|December 9, 2025
PubMed
Summary
This summary is machine-generated.

New safety helmet testing evaluates fall impacts, revealing Type II helmets significantly reduce head injury risks compared to Type I. The Construction STAR rating system differentiates helmet performance for better head protection.

Keywords:
ConcussionConstructionFallsHard hatHead accelerationObliqueRiskRotationalSkull fracture

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Area of Science:

  • Occupational Safety and Health
  • Biomechanics
  • Traumatic Brain Injury

Background:

  • Falls are the leading cause of work-related traumatic brain injuries (TBIs).
  • Current safety helmet standards do not adequately assess performance under fall-related impact conditions.
  • Existing tests fail to represent real-world fall scenarios, potentially compromising worker head protection.

Purpose of the Study:

  • To develop a novel test methodology for evaluating safety helmets under fall-representative impact conditions.
  • To introduce a Construction STAR rating system for quantitatively assessing helmet performance against concussion and skull fracture risks.
  • To provide a standardized method for comparing safety helmet efficacy in preventing fall-related head injuries.

Main Methods:

  • A multi-faceted approach combining literature review, OSHA accident data analysis, and oblique impact testing.
  • Development of a fall-specific helmet test methodology with defined impact locations, velocities (5.5 and 6.8 m/s), and a 25-degree anvil.
  • Application of the test to Type I and Type II helmet models, calculating STAR scores based on combined concussion and skull fracture risk.

Main Results:

  • Type II helmets demonstrated a 32.7% reduction in concussion risk and a 57.5% reduction in skull fracture risk compared to Type I helmets.
  • Significant performance variations were found among Type II helmets, with top models outperforming lower-ranked ones.
  • The STAR scores effectively differentiated helmet performance, highlighting the benefits of advanced designs for fall impacts.

Conclusions:

  • Type II safety helmets provide superior head protection against oblique, fall-related impacts compared to Type I models.
  • The proposed STAR rating system, incorporating both concussion and skull fracture risk, accurately distinguishes between high and low-performing safety helmets.
  • The developed test methodology offers a more realistic and effective means of assessing safety helmet efficacy for fall protection.