A new construction safety study funded by the John R. Gentille Foundation (JRGF) confirms a major performance gap between traditional Type I hard hats and modern Type II helmets. The findings show that Type II helmets reduce concussion risk by an average of 34% and skull fracture risk by 65%—and the top-performing models did even better, cutting skull fracture risk by up to 77%.
Falls remain one of the leading causes of fatalities and traumatic brain injuries in construction. According to the Bureau of Labor Statistics, the construction industry accounts for nearly 47% of all fatal slips, trips, and falls and 20% of all workplace deaths. In a trade where falls cause 60% of traumatic brain injury fatalities, this study confirms what many safety professionals have suspected: the industry needs to move beyond outdated hard hats.
Why Type II Helmets Perform Better
Type II helmets are designed to manage the kinds of forces that actually cause most head injuries in construction—especially rotational forces from angledimpacts during falls. Traditional Type I hard hats were never built for that. They were designed decades ago, mainly to protect against direct, top-of-head impacts, such as dropped objects.
The Virginia Tech results show the performance difference comes from three main design upgrades found in Type II helmets:
1. Energy-Absorbing Interior Liner
Type II helmets include an expanded polystyrene (EPS) or expanded polypropylene (EPP) foam liner similar to what is used in bike, ski, and climbing helmets.
- This liner absorbs force across the full inside surface of the helmet.
- It reduces both linear acceleration (straight impact) and rotational acceleration (twisting movement of the brain inside the skull).
- Type I hard hats have only a suspension cradle and air gap—no foam to disperse force.
2. Side, Front, and Rear Impact Protection
ANSI Type I helmets are only tested for impact at the crown of the head.
ANSI Type II helmets must pass impact tests on all four sides.
That matters because in real falls, workers rarely land straight down—most impacts happen at an angle, striking the back, side, or front of the helmet.
3. Required Chin Strap
A chin strap is optional on Type I helmets, but required for Type II.
- Without a chin strap, a hard hat often comes off before the head hits the ground.
- Helmet ejection is a known factor in fall-related deaths and severe TBIs.
- A secured helmet keeps the energy-absorbing liner in place when it’s needed most.
The Result in Data Terms
- Type I hard hats reduce almost no rotational force.
- Type II helmets reduce rotational force by up to 60–70%, depending on the model.
- That reduction is what drives the concussion and skull fracture reductions in the Virginia Tech study.
Why It Matters to Contractors
The change in performance isn’t incremental—it’s structural. This is the same evolution that happened in sports, where foam-lined helmets replaced shell-only helmets decades ago. The construction industry has simply been slow to adopt it. As one safety director in the study put it: “The old hard hat protects you from gravity. The Type II helmet protects you from physics.” These models feature technologies like EPP foam liners, Impact Armor systems, and integrated emergency ID chips.
How the Testing Works
This is the first-ever rating system for construction helmets based on real-world fall impacts. The John R. Gentille Foundation, along with multiple construction trade associations, partnered with Virginia Tech to make it happen.
The ratings are derived from the Summation of Tests for the Analysis of Risk (STAR) protocol. Here’s how helmets were tested:
- 12 oblique impact drops on a 25° angled steel surface coated in sandpaper
- Two impact speeds: 5.5 m/s (moderate) and 6.8 m/s (high)
- Measurements: Linear and rotational head acceleration
- Results: Calculated concussion and skull fracture risk based on 100 similar impacts
- Ratings: Helmets scoring 4 or 5 stars are recommended for workers exposed to fall hazards
Type II models consistently outperformed Type I hard hats under these conditions.
Why This Matters for Contractors
Upgrading from Type I hard hats to Type II helmets is not just a safety decision—it has direct financial and
operational impact for contractors. A single fall-related head injury can cost a company far more than the price
difference between helmets.
1. Cost of a Head Injury vs. Cost of a Helmet
The math is simple: one prevented injury pays for an entire company-wide upgrade.
2. Insurance and Experience Modifier (EMR) Impact
- Head injuries are one of the highest-cost claim categories in construction.
- A single severe claim can raise a contractor’s EMR for three years.
- A higher EMR means higher premiums and can disqualify contractors from bidding on large projects.
Contractors who adopt Type II helmets early will have a measurable advantage in prequalification scoring and insurance negotiation.
3. Owner and GC Requirements Are Coming
Large GCs and tech-sector owners (Amazon, Meta, Intel, data-center builders) are already phasing out Type I hard hats on their sites. Early adopters won’t be forced into rushed, reactive PPE changes later.
Bottom Line
Type II helmets are no longer a “nice to have.” They reduce injury probability, reduce insurance exposure, reduce legal risk, and reduce long-term cost. Contractors who continue relying on Type I hard hats are not saving money—they’re deferring risk.
What’s Next
The Virginia Tech Helmet Lab plans to expand testing to include struck-by-object incidents and will regularly update ratings as new helmets enter the market. These updates are independent, free from manufacturer influence, and designed to adapt as technology evolves.
The message is simple: it’s time for construction to upgrade from heavy plastic buckets to real head protection. Type II helmets are no longer just an option— they’re the new standard for anyone working at height.
Full helmet ratings and technical reports are available at the Virginia Tech Helmet Ratings website.
