BACKGROUND:Wearing protective helmets is an important prevention strategy to reduce work-related traumatic brain injuries. The existing standardized testing systems are used for quality control and do not provide a quantitative measure of the helmet performance. OBJECTIVE:To analyze the failure characterizations of Type I industrial helmets and develop a generalized approach to quantify the shock absorption performance of Type I industrial helmets based on the existing standardized setups. METHODS:A representative basic Type I construction helmet model was selected for the study. Top impact tests were performed on the helmets at different drop heights using two different impactor masses (3.6 and 5.0 kg). RESULTS:When the helmets were impacted with potential impact energies smaller than the critical potential impact energy values, there was a consistent relationship between the peak impact force and the potential impact energy. When the helmets were impacted under potential impact energies greater than the critical potential impact energy values, the peak impact forces increased steeply with increasing potential impact energy. CONCLUSION:A concept of safety margin for construction helmets based on potential impact energy was introduced to quantify the helmets' shock absorption performance. The proposed method will help helmet manufacturers improve their product quality.

Mast climbing work platforms (MCWPs) have been increasingly used for construction projects, whereas their safety remains an important issue. As the mast in the Mast climbing work platform (MCWP) system is “slender” structurally, its anchorages must play an important role in maintaining its stability. Therefore, the anchorages and their attachments to a construction structure are likely among the most critical components for the MCWPs. This study developed finite element models of a representative MCWP and applied them to analyze the characteristics of the reaction forces at the anchorages when the work platform operates at different heights and under different loading conditions and to simulate the mast structure responses to the failure of one of the three anchorages. The results of this study indicate that the anchorage reaction forces are sensitive to the loading and operational conditions of the MCWP. The responses of the anchorage reaction forces may reflect the stability status or risk potential of the mast structure of the MCWP to collapse. The characteristics of the anchorage forces identified in this study can be used to help develop a structural safety monitoring system, to minimize the risk of catastrophic failures of MCWPs. The knowledge obtained in the study would help improve MCWP safety management at construction sites and help MCWP manufacturers to improve anchorage design and installation procedures to reduce the risk of the mast structure’s instability or collapse.

Mast climbing work platforms (MCWPs) have been widely used at construction sites in the United States since the 1980s.The purpose of the current study is to analyze the effects of a failure of an anchorage on the structural stability of a mast climber system using the finite element (FE) method.The FE models were constructed using commercial software (ABAQUS) and based on representative set-ups of anchored MCWPs as specified in the manufacturers' manuals.The simulated MCWP has three anchorages, and one is assumed to fail.The consequences of an anchorage failure were evaluated numerically.Our results show that the failure of an anchorage caused loading redistributions among the remaining anchorages.Although the reaction forces and moments in the supporting feet for the remaining anchorages increased slightly due to the failure of an anchorage, the structure stiffness decreased remarkably due to the anchorage failure.

The performance of Type I industrial helmets for fall protection is not required to be tested in standardized tests. The current study analyzed the fall protection performance of Type I industrial helmets and evaluated if the use of a chin strap and the suspension system tightness have any effect on protection performance. Head impact tests were performed using an instrumented manikin. There were 12 combinations of test conditions: with or without chin strap usage, three levels of suspension system tightness, and two impact surfaces. Four representative helmet models (two basic and two advanced models) were selected for the study. Impact tests without a helmet under all other applicable test conditions were used as a control group. There were four replicates for each test condition-a total of 192 impact tests with helmets and eight impact tests for the control group. The peak acceleration and the calculated head impact criteria (HIC) were used to evaluate shock absorption performance of the helmets. The results showed that all four helmet models demonstrated excellent performance for fall protection compared to the barehead control group. The fall protection performance of the advanced helmet models was substantially better than the basic helmet models. However, the effects of the use of chin straps and suspension system tightness on the helmets' fall protection performance were statistically not significant.

The objective of this study was to assess the impact of using alternative mast climbing work platform (MCWP) designs on trunk motion and postural stability with masonry workers while performing bricklaying and stepping down tasks using a conventional MCWP setting (i.e. with a step deck) as well as two types of production tables (straight- and L-shaped). The trunk angles and postural sway parameters of twenty-five masonry workers were recorded for the following tasks: (1) standing on a simulated MCWP and laying bricks on an adjacent wall, and (2) stepping down onto the step deck to get into position for doing the bricklaying task. Results indicated that the use of the L-shaped production table resulted in the lowest trunk ranges of motion and significantly reduced the workers' trunk angles in all three planes when compared to both the straight-shaped production table and the conventional approach of not using a production table. Data showed that both body sway velocity and area were significantly reduced when using either one of the production tables. The use of production tables significantly reduced impact sway forces when workers stepped from the main platform to the step deck. The use of production tables on MCWPs improved workers' postures and overall stability, which could reduce the risk of injury.

The helmets used by construction site workers are mainly designed for head protection when objects are dropped from heights. Construction helmets are also casually called "hard hats" in industries. Common construction helmets are mostly categorized as type 1 according to different standards. All type 1 helmets have to pass type 1 standard impact tests, which are top impact tests-the helmet is fixed and is impacted by a free falling impactor on the top crown of the helmet shell. The purpose of this study was to develop an approach that can determine the performance characterization of a helmet. A total of 31 drop impact tests using a representative type 1 helmet model were performed at drop heights from 0.30 to 2.23 m, which were estimated to result in impact speeds from 2.4 to 6.6 m/s. Based on our results, we identified a critical drop height that was used to evaluate the performance of helmets. The peak impact forces and peak accelerations varied nonproportionally with the drop height. When the drop height is less than the critical height, the peak force and peak acceleration increase gradually and slowly with increasing drop height. When the drop height is greater than the critical height, the peak force and peak acceleration increase steeply with even a slight increase in drop height. Based on the critical drop height, we proposed an approach to determine the safety margin of a helmet. The proposed approach would make it possible to determine the performance characteristics of a helmet and to estimate the safety margin afforded by the helmet, if the helmet first passes the existing standardized tests. The proposed test approach would provide supplementary information for consumers to make knowledgeable decisions when selecting construction helmets.

BACKGROUND:The use of helmets was considered to be one of the important prevention strategies employed on construction sites. The shock absorption performance of a construction (or industrial) helmet is its most important performance parameter. Industrial helmets will experience cumulative structural damage when being impacted repeatedly with impact magnitudes greater than its endurance limit. OBJECTIVE:The current study is to test if the shock absorption performance of Type I construction helmets subjected to repeated impacts can be improved by applying polyethylene air-bubble cushions to the helmet suspension system. METHODS:Drop impact tests were performed using a commercial drop tower test machine following the ANSI Z89.1 Type I drop impact protocol. Typical off-the-shelf Type I construction helmets were evaluated in the study. A 5 mm thick air-bubble cushioning liner was placed between the headform and the helmet to be tested. Helmets were impacted ten times at different drop heights from 0.61 to 1.73 m. The effects of the air-bubble cushioning liner on the helmets' shock absorption performance were evaluated by comparing the peak transmitted forces collected from the original off-the-shelf helmet samples to the helmets equipped with air-bubble cushioning liners. RESULTS:Our results showed that a typical Type I construction helmet can be subjected to repeated impacts with a magnitude less than 22 J (corresponding to a drop height 0.61 m) without compromising its shock absorption performance. In comparison, the same construction helmet, when equipped with an air-bubble cushioning liner, can be subjected to repeated impacts of a magnitude of 54 J (corresponding to a drop height 1.52 m) without compromising its shock absorption performance. CONCLUSIONS:The results indicate that the helmet's shock absorbing endurance limit has been increased by 145% with addition of an air-bubble cushioning liner.

The industrial helmet is the most used and effective personal protective equipment to reduce work-related traumatic brain injuries. The Type I industrial helmet is a basic helmet model that is commonly used in construction sites and manufacturers. The purpose of the current study was to investigate if shock absorption performance of these helmets could be improved by using an air-bubble cushioning liner to augment the helmet's suspension system. Drop impact tests were performed using a commercial drop tower test machine according to the ANSI Z89.1 Type I drop impact protocol. Typical off-the-shelf Type I industrial helmets were utilized in the study. The effects of the air-bubble cushioning on the helmets' shock absorption performance were evaluated by comparing the original off-the-shelf helmet samples to the helmets equipped with an air-bubble cushioning liner. The air-bubble cushioning liner (thickness 5 mm) was placed between the headform and the helmet when being tested. The impactor had a mass of 3.6 kg and was free-dropped from different heights. The maximal peak transmitted forces for each of the tests have been evaluated and compared. Our results show that the shock absorption effectiveness of the air-bubble cushioning is dependent on the magnitude of the impact force. At lower drop heights (h < 1.63 m), the air-bubble cushioning liner has little effect on the transmitted impact forces, however, at higher drop heights (h >= 1.73 m) the air-bubble cushioning liner effectively reduced the peak transmitted forces. At a drop height of 1.93 m (the highest drop height tested), the air-bubble cushioning liner reduced the peak transmitted force by over 80%. Our results indicate that adding an air-bubble cushioning liner into a basic Type I industrial helmet will substantially increase shock absorption performance for large impact forces.

Helmets have been considered one of the important prevention strategies in construction to reduce work-related traumatic brain injury risk. Top impacts are considered essential tests to evaluate the shock absorption performance of commonly used industrial helmets. Currently, there are two major test standards that are widely applied in industry: the U.S. standard ANSI/ISEA Z89.1 and the European standard EN397. Since drop impacts are performed using different impactor mass and drop heights, results obtained from two different test standards are quite different. The purpose of the current study is to analyze, evaluate, and compare the test results obtained using these two frequently used helmet test standards. A representative basic Type I construction helmet model was selected for the study. A total of 23 drop impact tests were performed at different drop heights and in two groups using two different impactor masses: (a) fifteen drop impacts were performed using an impactor mass of 3.6 kg at drop heights from 0.30 m to 2.23 m and (b) eight drop impacts were performed using an impactor mass of 5.0 kg at drop heights from 0.22 m to 1.35 m. Relationships between the drop height and the maximal transmitted force for two test groups were analyzed. When test data were plotted in the peak force and peaks accelerations as a function of impact kinetic energy, all test results for groups (a) and (b) fall narrowly on the same curve. Our results showed a consistent trend for the relationship of maximal transmitted force and accelerations as a function of the impact kinetic energy, independent of the impactor mass. When the impact energy is smaller than the critical impact energy, the peak impact forces and peak accelerations increase gradually and slowly with increasing impact energy; when the impact energy is greater than the critical impact energy, the peak impact forces and peak accelerations increase steeply with increasing impact energy.

It is accepted in industries that an industrial helmet should be disposed of when it is subjected to a significant impact. There is no scientific evidence that supports this well-accepted belief. The current study was intended to evaluate the shock absorption performance of industrial helmets under repeated impacts. Common industrial or construction helmets are categorized as Type I according to ANSI Z89.1 and they are designed to mainly protect top impacts. A representative basic Type I construction helmet model was selected in the study. Helmets were repeatedly impacted ten times using a commercial drop tower tester with an impactor (mass 3.6 kg) at different drop heights from 0.30 to 2.03 m. A total of 80 impact trials were performed in the study. The relationships of the transmitted force with the drop height and with impact number were analyzed. A new parameter - the endurance limit - was proposed to evaluate the shock absorption performance of a helmet. The helmets were observed to experience cumulative structural damage with increasing impact number, resulting in a degrading shock absorption performance, when being impacted repeatedly with magnitudes greater than the endurance limit. Repeated impacts with magnitudes smaller than the endurance limit did not cause measurable cumulative structural damage to the helmets in our study.

Workers are at risk when entering (ingress) or exiting (egress) elevated scissor lifts. In this study, we recorded ground impact forces and postural sway from 22 construction workers while they performed ingress and egress between a scissor lift and an adjacent work surface with varying conditions: lift opening designs, horizontal and vertical gaps, and sloped work surfaces. We observed higher peak ground shear forces when using a bar-and-chain opening, with larger horizontal gap, with the lift surface more than 0.2 m below the work surface, and presence of a sloped (26°) work surface. Similar trends were observed for postural sway, except that the influence of vertical distance was not significant. To reduce slip/trip/fall risk and postural sway of workers while ingress or egress of an elevated scissor lift, we suggest scissor lifts be equipped with a gate-type opening instead of a bar-and-chain design. We also suggest the lift surface be placed no more than 0.2 m lower than the work surface and the horizontal gap between lift and work surfaces be as small as possible. Selecting a non-sloped surface to ingress or egress a scissor lift is also preferred to reduce risk.

The finite element (FE) method has been widely used to investigate the mechanism of traumatic brain injuries (TBIs), because it is technically difficult to quantify the responses of the brain tissues to the impact in experiments. One of technical challenges to build a FE model of a human head is the modeling of the cerebrospinal fluid (CSF) of the brain. In the current study, we propose to use membrane elements to construct the CSF layer. Using the proposed approach, we demonstrate that a head model can be built by using existing meshes available in commercial databases, without using any advanced meshing software tool, and with the sole use of native functions of the FE package Abaqus. The calculated time histories of the intracranial pressures at frontal, posterior fossa, parietal, and occipital positions agree well with the experimental data and the simulations in the literature, indicating that the physical effects of the CSF layer have been accounted for in the proposed modeling approach. The proposed modeling approach would be useful for bioengineers to solve practical problems.

Traumatic brain injuries are among the most common severely disabling injuries in the United States. Construction helmets are considered essential personal protective equipment for reducing traumatic brain injury risks at work sites. In this study, we proposed a practical finite element modeling approach that would be suitable for engineers to optimize construction helmet design. The finite element model includes all essential anatomical structures of a human head (i.e. skin, scalp, skull, cerebrospinal fluid, brain, medulla, spinal cord, cervical vertebrae, and discs) and all major engineering components of a construction helmet (i.e. shell and suspension system). The head finite element model has been calibrated using the experimental data in the literature. It is technically difficult to precisely account for the effects of the neck and body mass on the dynamic responses, because the finite element model does not include the entire human body. An approximation approach has been developed to account for the effects of the neck and body mass on the dynamic responses of the head–brain. Using the proposed model, we have calculated the responses of the head–brain during a top impact when wearing a construction helmet. The proposed modeling approach would provide a tool to improve the helmet design on a biomechanical basis.

Mast Climbing Work Platforms (MCWPs) are becoming more common at construction sites and are being used as an alternative to traditional scaffolding. Although their use is increasing, little to no published information exists on the potential safety hazards they could pose for workers. As a last line of defense, a personal fall-arrest system can be used to save a worker in a fall incident from the platform. There has been no published information on whether it is safe to use such a personal fall-arrest system with MCWPs. In this study, the issues of concern for occupational safety included: (a) the overall stability of the freestanding mast climber during a fall-arrest condition and (b) whether that fall-arrest system could potentially present safety hazards to other workers on the platform during a fall-arrest condition. This research project investigated those safety concerns with respect to the mast climber stability and the workers using it by creating fall-arrest impact forces that are transmitted to the equipment and by subsequently observing the movement of the mast climber and the working deck used by the workers. This study found that when the equipment was erected and used according to the manufacturer's recommendations during a fall-arrest condition, destabilizing forces were very small and there were no signs of potential of MCWP collapse. However, potential fall hazards could be presented to other workers on the platform during a fall arrest. Workers near an open platform are advised to wear a personal fall-arrest system to reduce the risk of being ejected. Due to the increasing use of MCWPs at construction sites, there is a corresponding need for evidence and science-based safety guidelines or regulations and further research should be conducted to continue to fill the knowledge gap with MCWP equipment.

Inverse dynamics models used to investigate musculoskeletal disorders associated with handle gripping require accurate phalangeal kinetics. Cylindrical handles wrapped with pressure film grids have been used in studies of gripping kinetics. We present a method fusing six degree-of-freedom hand kinematics and a kinematic calibration of a cylinder-wrapped pressure film. Phalanges are modeled as conic frusta and projected onto the pressure grid, automatically segmenting the pressure map into regions of interest (ROIs). To demonstrate the method, segmented pressure maps are presented from two subjects with substantially different hand length and body mass, gripping cylinders 50 and 70 mm in diameter. For each ROI, surface-normal force vectors were summed to create a reaction force vector and center of pressure location. Phalangeal force magnitudes for a data sample were similar to that reported in previous studies. To evaluate our method, a surrogate was designed for each handle such that when modeled as a phalanx it would generate a ROI around the cells under its supports; the classification F-score was above 0.95 for both handles. Both the human subject results and the surrogate evaluation suggest that the approach can be used to automatically segment the pressure map for quantifying phalangeal kinetics of the fingers during cylindrical gripping.

INTRODUCTION Traumatic brain injuries (TBI) are among the most common severely disabling injuries in the U.S. Approximately 1.7 million cases occurred in civilians annually during 2002-2006 [1]. Construction helmets are considered as essential personal protective equipment to reduce TBI risks at work sites. Despite wide applications of the finite element (FE) modeling in the study of the injury mechanisms of TBI [2] and in the design of sport [3] or military helmets [4], there is limited analytical study of the construction helmet [5]. In the current study, we proposed a practical FE modeling approach that would be suitable for engineers to optimize construction helmet design.

Objective: The current study is intended to evaluate the stability of a scissor lift and the performance of various fall-arrest harnesses/lanyards during drop/fall-arrest conditions and to quantify the dynamic loading to the head/neck caused by fall-arrest forces. Background: No data exist that establish the efficacy of fall-arrest systems for use on scissor lifts or the injury potential from the fall incidents using a fall-arrest system. Method: The authors developed a multibody dynamic model of the scissor lift and a human lift operator model using ADAMS™ and LifeMOD™ Bio-mechanics Human Modeler. They evaluated lift stability for four fall-arrest system products and quantified biomechanical impacts on operators during drop/fall arrest, using manikin drop tests. Test conditions were constrained to flat surfaces to isolate the effect of manikin-lanyard interaction. Results: The fully extended scissor lift maintained structural and dynamic stability for all manikin drop test conditions. The maximum arrest forces from the harnesses/lanyards were all within the limits of ANSI Z359.1. The dynamic loading in the lower neck during the fall impact reached a level that is typically observed in automobile crash tests, indicating a potential injury risk for vulnerable participants. Conclusion: Fall-arrest systems may function as an effective mechanism for fall injury protection for operators of scissor lifts. However, operators may be subjected to significant biomechanical loadings on the lower neck during fall impact. Application: Results suggest that scissor lifts retain stability under test conditions approximating human falls from predefined distances but injury could occur to vulnerable body structures.