Virginia Tech Lab Aims to Advance Construction Helmet Testing as Industry Stresses OSHA Standards
A new Virginia Tech laboratory is testing construction helmets under real-world impact scenarios to improve safety data, but industry leaders caution that ratings should complement—not replace—established OSHA and ANSI/ISEA standards.
- By Stasia DeMarco
- Sep 30, 2025
Virginia Tech researchers have launched a specialized laboratory to enhance the way construction helmets are tested and rated, aiming to better predict real-world performance in jobsite impacts. The lab will simulate a variety of impact conditions, from angled strikes to side blows, and compare helmet models side-by-side using advanced instrumentation.
According to project leads, existing standards often focus on vertical impacts, which may not fully capture the complex dynamics of falls and debris strikes commonly seen in construction environments. The new test rig lets engineers evaluate how helmets perform under different angles, energies, and durations — producing data that could inform future industry standards and product design.
Helmet manufacturers and safety professionals alike say the lab’s insights could drive improvements in protective headgear, helping lower head injury rates in high-risk industries. Project organizers aim to publish comparative ratings and detailed performance metrics to guide procurement decisions and promote better helmet selection in real work settings.
However, industry leaders caution that the Virginia Tech ratings should be viewed as supplemental rather than a replacement for existing regulatory standards. Cam Mackey, President and CEO of the International Safety Equipment Association (ISEA), emphasized the distinction between research data and compliance requirements.
“We appreciate the work Virginia Tech has done to help advance understanding of head protection. Their new Construction Helmet Ratings provide some interesting data about certain types of fall impacts. But it’s really important to understand what this study is — and what it isn’t,” Mackey said. “OSHA requires workers to wear helmets that meet ANSI/ISEA Z89.1, which is the official standard for workplace head protection, when head protection is required. The Virginia Tech study doesn’t test for that standard. Instead, it uses a single method for all helmets, including Type I helmets, designed to protect against falling objects, and Type II helmets, designed to protect against falling objects and from side impacts. These products are designed to protect workers from different exposures. When you test these different products the exact same way, you can end up with results that don’t tell the full story. A helmet with fewer stars can still protect workers, be fully compliant with OSHA rules, and completely appropriate for many jobsite hazards.”
Mackey added that employers and workers should always begin with a job hazard analysis and ensure compliance with OSHA and ANSI/ISEA Z89.1 standards. “Ratings like Virginia Tech’s can be helpful as additional information, but they don’t replace the standard or the rigorous process behind it,” he noted.
ISEA and its members are currently revising the ANSI/ISEA Z89.1 standard to incorporate enhanced testing for helmets with advanced protective features. The updated standard, expected early next year, aims to ensure workers have access to a broad range of safe, high-performance helmets as jobsite risks continue to evolve.
About the Author
Stasia DeMarco is the Content Editor for OH&S.