Why do some helmets reduce the risk of skull fractures by as much as 75 percent? The answer comes down to how they are tested.
A new video in the John R. Gentille Foundation’s Construction Helmet Research Program series takes viewers inside the science behind the Virginia Tech Helmet Ratings system. In the episode, Dr. Barry Miller and Dr. Steve Rowson explain how researchers developed a testing methodology that reflects how serious head injuries actually occur on construction sites.
To build the testing protocol, researchers analyzed years of accident data and incident reports involving falls and head impacts. These incidents often involve a worker striking the ground or another surface during a fall. Using that data, the Virginia Tech team designed laboratory tests that replicate those real-world scenarios.
Each helmet is tested across multiple impact locations and speeds. The results are then used to calculate the predicted risk of concussion and skull fracture. Those results are combined into a STAR score, short for Summation of Tests for the Analysis of Risk, which estimates how well a helmet reduces injury risk in realistic impact conditions.
Helmets are then assigned a one-to-five star rating, making it easier for contractors and workers to compare different models.
The research has also highlighted a key difference between traditional hard hats and modern construction helmets. Type II helmets, which provide protection from both top and side impacts, generally perform significantly better in fall scenarios than traditional Type I hard hats, which are designed primarily for top impacts. In testing, Type II helmets were shown to reduce the risk of skull fractures by as much as 75 percent and significantly reduce the risk of concussion compared to many traditional Type I hard hats.
The Construction Helmet Research Program is supported by the John R. Gentille Foundation, ELECTRI International, The Association of Union Constructors, and the American Society of Concrete Contractors. The goal is simple: provide independent data that helps contractors make informed decisions about head protection.
For more information on the testing and results, visit the Virginia Tech Helmet Lab.
