A growing concern over worker safety in the construction industry has been underscored by new research showing that nearly half of construction helmets in use may not provide sufficient protection. The findings come as the U.S. Bureau of Labor Statistics reports that one in five workplace deaths in 2023 occurred in construction.
To better understand how head injuries can be prevented, engineers at Virginia Tech’s Helmet Lab conducted an 18-month study examining helmet performance in real-world fall conditions.
Researchers tested 17 helmet models by simulating falls from 14 and 25 feet — heights consistent with ladder, scaffold, or platform accidents.
“And these are falls that are somewhat severe, but survivable,” said Barry Miller, director of outreach at the Helmet Lab.
The helmets were evaluated based on impact absorption, retention, and likelihood of preventing concussions or skull fractures.
A major finding centered on type I safety helmets, which are still widely used on job sites.
Miller explained that many workers rely on this style:
“They [typically] don’t have a chin strap, and no peripheral padding materials.”
Of the 17 helmets tested, 8 were type I, and results showed these models are 50% less likely to protect workers from head injuries caused by falls compared with type II helmets.
One key issue: without chin straps, type I helmets can easily dislodge during a fall. Their reduced padding also limits impact absorption.
Cost is one reason these older helmets remain popular — type I models are generally cheaper than type II.
In 2023, the U.S. Department of Labor's Occupational Safety and Health Administration (OSHA) formally recommended that workers transition to type II safety helmets, which offer greater protection around the sides and back of the head.
The Virginia Tech study was funded by multiple construction trade organizations, aiming to better understand safety outcomes across helmet categories.
“This gives them some objective criteria to help move to better, safer helmets,” Miller said.
He compared the potential shift to what happened in football, where major advances followed evidence-based helmet ratings.
Miller acknowledged that while improved padding is essential, weight and long-term comfort must also be considered.
“You know, a little bit more padding can go a long way to reducing concussion risk and skull fracture,” he said.
Of the helmets tested, seven received a five-star safety rating, indicating best-in-class performance.
Miller confirmed that the Helmet Lab is already working with helmet manufacturers interested in using the study to enhance future models.
With falls remaining one of the most common — and deadly — construction hazards, the research is expected to influence procurement decisions, safety policies, and training across the sector.
Originally reported by Roxy Todd in WVTF News.
.webp)
