8/10/2019 ANSI-IsEA Z89.

1 (2009) - American National Standard for Industrial Head Protection

 A N S I / I S E A Z89.1-2009

 American National Standard

for Industrial Head Protection

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ANSI/ISEA Z89.1-2009
Revision of
ANSI Z89.1-2003

American National Standard 

for Industrial Head Protection 

Secretariat
International Safety Equipment Association 

 Approved January 26, 2009

American National Standards Institute, Inc.

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An American National Standard implies a consensus of those substantially

American concerned with its scope and provisions. An American National Standard is
National intended as a guide to aid the manufacturer, the consumer, and the general
public. The existence of an American National Standard does not in any respect
Standard preclude anyone, whether they have approved the standard or not, from
manufacturing, marketing, purchasing, or using products, processes, or
procedures not conforming to the standard. American National Standards are
subject to periodic review and users are cautioned to obtain the latest editions.

The American National Standards Institute does not develop standards and will in
no circumstances give an interpretation of any American National Standard.
Moreover, no persons shall have the right or authority to issue an interpretation of
an American National Standard in the name of the American National Standards
Institute.

CAUTION NOTICE: This American National Standard may be revised or

withdrawn at any time. The procedures of the American National Standards
Institute require that action be taken to reaffirm, revise, or withdraw this standard
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Published by

International Safety Equipment Association

1901 North Moore Street, Suite 808, Arlington, Virginia 22209 

Copyright © 2009 by International Safety Equipment Association

All rights reserved.

No part of this publication may be reproduced in any

form, in an electronic retrieval system or otherwise, without
the prior written permission of the publisher.

Printed in the United States of America

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Foreword (This Foreword is not part of ANSI/ISEA Z89.1-2009)

Voluntary industry consensus standards recognized by the American National Standards Institute are
required to be reviewed every five years to account for improvements in technology, test methods and
materials, user needs and trends in use and application of products covered under the respective
standard. This
 ANSI/ISEA sixth revision
Z89.1-2009 American
of the an
represents effort toNational Standard
accommodate for IndustrialofHead
characteristics Protection,
industrial head  
protection that end-users identified as being important as work environments change and emerging
hazards are identified. This 2009 edition was prepared by the ISEA Head Protection Group whose
current members include: 3M Company, Bullard, ERB Industries, Gateway Safety, Jackson Safety,
MSA, North by Honeywell, OccuNomix International, Sellstrom Manufacturing Co., and Sperian
Protection.

This version of ANSI/ISEA Z89.1-2009 incorporates optional testing and marking features for head
protection devices. Notable among these are specific testing protocols and marking for products that
have high-visibility properties. Criteria for these products are based on well-established test methods
found in other industry standards. Additionally, criteria have been incorporated for products that can be
worn in the reverse position and those that are exposed to lower temperatures than the standard test
temperatures.

This standard was processed and approved using consensus procedures prescribed by the
 American National Standards Institute. The following organizations were contacted prior to the
approval of this standard. Inclusion in this list does not necessarily imply that the organization
concurred with the submittal of the proposed standard to ANSI.

 APM Terminals Intertek Testing Services

 Atlas Industrial Contractors National Personal Protective Technologies Laboratory
City of San Diego Parsons Brinckerhoff
Entergy Services Incorporated Safety Equipment Institute
ICS Laboratories, Inc. Underwriters Laboratories, Inc.
International Safety Equipment Association Ms. Camille Villanova

Suggestions for improvement of this standard are encouraged. Contact:

ISEA
1901 N. Moore Street #808
 Arlington, VA 22209
standards@safetyequipment.org

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Contents 
SECTION PAGE
1. Scope, Purpose and Limitations................................................................................. 1
1.1 Scope.................................................................................................................. 1
1.2 Purpose............................................................................................................... 1
1.3 Limitations........................................................................................................... 1
2 Compliance ................................................................................................................. 1
3. Definitions ................................................................................................................... 1
4. Types and Classes ..................................................................................................... 2
4.1 Impact Types ...................................................................................................... 2
4.2 Electrical Classes ............................................................................................... 2
4.3 Reverse Wearing ................................................................................................ 3
5. Accessories................................................................................................................. 3
6. Instructions and Markings........................................................................................... 3
7. Performance Requirements........................................................................................ 3
7.1 Requirements for Type I and Type II Helmets.................................................... 3
7.2 Additional Requirements for Type II Helmets..................................................... 4
7.3 Requirements for Optional Testing..................................................................... 4
8. Selection and Preparation of Test Samples ............................................................... 4
8.1 Headforms .......................................................................................................... 4
8.2 Test Samples...................................................................................................... 5
8.3 Test Sample Markings........................................................................................ 5
8.4 Helmet Preconditioning....................................................................................... 6
9. Test Methods .............................................................................................................. 7
9.1 Flammability........................................................................................................ 7
9.2 Force Transmission ............................................................................................ 7
9.3 Apex Penetration ................................................................................................ 8
9.4 Impact Energy Attenuation ................................................................................. 9
9.5 Off-Center Penetration......................................................................................11
9.6 Chin Strap Retention (Type II Only) ................................................................. 11
9.7 Electrical Insulation........................................................................................... 12
9.8 High-Visibility Testing ....................................................................................... 13
10. Normative References .............................................................................................. 13

TABLES
Table 1. Color, High Visibility Helmets ............................................................................ 4
Table 2. Sizing Chart ...................................................................................................... 14
Table 3. Schedule of Tests ............................................................................................. 15

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FIGURES
1. ISO Headform ........................................................................................................... 17
2. Dynamic Test Line (DTL), Impact and Penetration Tests ........................................ 18
3. Force Transmission Headform ................................................................................. 19
4. Typical Impact Energy Attenuation Headform Fixture .............................................. 20

5. Typical Penetration Headform Fixture ...................................................................... 20

6. Chin Strap Retention Test Apparatus....................................................................... 21
7. Typical Force Transmission Test Apparatus ............................................................ 22
8. Typical Penetration Test Apparatus.......................................................................... 23
9. Typical Penetrator..................................................................................................... 24
10. Typical Impact Energy Attenuation Apparatus ......................................................... 25
11. Static Test Line (STL), Electrical Insulation and Flammability Tests........................26
112. Flammability Test Apparatus .................................................................................... 26

 APPENDICES
 A. Recommendations, Cautions, Use and Care ...................................................A1
B. Electrical Insulation Testing..............................................................................A3
C. Force Transmission Testing .............................................................................A4
D. Impact Energy Attenuation Testing ..................................................................A6
E. Test Equipment Sources ..................................................................................A8

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American National Standard
for Industrial Head Protection
1. Scope, Purpose and Limitations
1.1 Scope
This standard describes Types and Classes,
testing and performance requirements for
protective helmets. These include
recommended safety requirements for
authorities considering the establishment of
regulations or codes concerning the use of
protective helmets.
1.2 Purpose
This standard establishes minimum
performance requirements for protective
helmets that reduce the forces of impact and
penetration and that may provide protection
from electric shock.
1.3 Limitations
Protective helmets reduce the amount of force
from an impact blow but cannot provide
complete head protection from severe impact
and penetration. Helmets that meet this
standard provide limited protection but should
be effective against small tools, small pieces of
wood, bolts, nuts, rivets, sparks and similar
hazards. The use of protective helmets should
never be viewed as a substitute for good safety
practices and engineering controls. Alterations,
attachments, or additions of accessories may
affect the performance of the helmet. Helmets
are designed to provide protection above the
test lines, which are clearly defined in the
standard. Helmets may extend below the test
lines for styling or practical purposes but no
protection is to be implied below the test lines.
2. Compliance
 Any statement(s) of compliance with this
standard shall mean that the product meets all
applicable requirements for the Type and Class.
It is specifically intended that partial utilization of
this standard is prohibited.
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 ANSI/ISEA Z89.1-2009
3. Definitions
accessory:  A device intended to be mounted
on or used with protective helmets. (See Section
5)
apex:  The point on the outer surface of the
shell coincident with the vertical axis of the
headform when mounted in the as-worn position
according to the manufacturer's instructions.
basic plane:  A plane at the level of the external
auditory meatus (external ear opening) and the
inferior margin of the orbit (lower edge of the
eye socket).
brim:  An integral part of a helmet shell
extending outward around the entire
circumference of the lower shell.
chin strap:   A strap which fits under the chin
and is attached to the helmet.
crown straps:  The part of the suspension that
passes over the head.
dynamic test line (DTL):  A test line used as a
boundary for conducting impact energy
attenuation and off-center penetration tests.
flammability:  The ability of a helmet shell to
support combustion upon removal of the test
flame.
harness:  The complete assembly used to
maintain a helmet in correct wearing position on
the wearer's head, exclusive of a chin strap or
other retention device.
headband:  The part of the harness that
encircles the head.
helmet:  A device worn on the head designed to
provide limited protection against impact, flying
particles or electric shock.
manufacturer:  The business entity that marks
or directs the permanent marking of the
components or complete device as compliant
with this standard and sells them as compliant.
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midsagittal plane:  A longitudinal plane,
perpendicular to the basic plane, which passes
through the vertex and geometrically bisects the
head.
nape strap:  A strap that fits behind the head
below the reference plane.
peak:  A part of the shell extending forward over
the wearer's forehead.
positioning index:  A perpendicular distance,
as specified by the manufacturer, from some
point on the helmet to the basic plane when the
helmet is properly seated on a reference
headform.
projection:  Rigid features that extend or
protrude beyond the normal internal or external
surface or contour of the helmet.
protective padding:  Any material used to
absorb the kinetic energy of impact.
reference plane:  A plane at a given distance
above and parallel to the basic plane.
reference headform:  A measuring device
contoured to specified dimensions with surface
markings indicating the locations of the basic,
midsagittal and reference planes, as well as any
required test lines.
shall:  In this standard, use of the word "shall"
indicates a mandatory requirement.
shell:  The part of a helmet which includes the
outermost surface.
should:  In this standard, use of the word
"should" indicates a recommendation.
suspension:  The portion of the harness which
is designed to act as an energy-absorbing
mechanism. It may consist of crown straps,
protective padding, or a similar mechanism.
static test line (STL):   A test line used as a
boundary for conducting electrical insulation,
flammability tests and for mounting for the force
transmission test. 
test line:  A line or combination of lines marked
on a reference headform used to provide limits
or a boundary beyond which protection is not
considered.
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test plaque:  A sample of the helmet or
representative shell material with a thickness of
3 mm ± 0.5 mm.
4. Types and Classes
Protective helmets are described by impact type
and electrical class. All protective helmets shall
meet either Type I or Type II requirements. All
helmets shall be further classified as meeting
Class G, Class E, or Class C electrical
requirements. Helmets meeting the reverse
wearing testing requirements shall be marked
with the reverse wearing mark. For example:
Type I, Class G or Type II, Class E LT.
4.1 Impact Types
4.1.1 Type I
Type I helmets are intended to reduce the force
of impact resulting from a blow only to the top of
the head.
4.1.2 Type II
Type II helmets are intended to reduce the force
of impact resulting from a blow to the top or
sides of the head.
4.2 Electrical Classes
4.2.1 Class G (General)
Class G helmets are intended to reduce the
danger of contact with low voltage conductors.
Test samples shall be proof-tested at 2200 volts
(phase to ground). This voltage is not intended
as an indication of the voltage at which the
helmet protects the wearer.
4.2.2 Class E (Electrical)
Class E helmets are intended to reduce the
danger of contact with higher voltage
conductors. Test samples are proof-tested at
20,000 volts (phase to ground). This voltage is
not intended as an indication of the voltage at
which the helmet protects the wearer.
4.2.3 Class C (Conductive)
Class C helmets are not intended to provide
protection against contact with electrical
hazards.
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 ANSI/ISEA Z89.1-2009

7.2 Additional Requirements for Type II

Helmets Table 1. Color, High-Visibility Helmets

7.2.1 Impact Energy Attenuation Color Chromaticity Minimum

coordinates total
Type II helmets shall be tested in accordance luminance
with Section 9.4 anywhere above the DTL. factor
 Acceleration shall be recorded. Maximum
x y Y (%)
acceleration shall not exceed 150 Gs.
Fluorescent 0.387 0.610 70
yellow-green 0.356 0.494
7.2.2 Off-center Penetration
0.398 0.452
0.460 0.540
Type II helmets shall be tested in accordance
Fluorescent 0.610 0.390 40
with Section 9.5 anywhere above the DTL.
orange-red 0.535 0.375
0.570 0.340
For each condition specified, the penetrator
0.655 0.344
shall not make contact with the test headform
when struck anywhere above the DTL. Fluorescent 0.655 0.344 25
red 0.570 0.340
0.595 0.315
7.2.3 Chin Strap 0.690 0.310
Chin straps shall be made of suitable material
not less than 12.7 mm (0.50 in.) in width. 
8 Selection and Preparation of Test
Type II helmets which are provided with chin Samples
straps shall be tested for retention in
accordance with Section 9.6. 8.1 Headforms

For each condition specified, the chin strap shall 8.1.1 General
remain intact. The residual elongation of the
strap shall not exceed 25 mm (1.0 in.). Only that part of the headform above the
reference plane is intended to represent the
7.3 Requirements for Optional Testing human head. Damaged or deformed headforms
shall not be used. Sources of headforms are
7.3.1 Reverse Wearing listed in Appendix E.

Type I Helmets that are to be marked with the 8.1.2 Headform sizes
reverse wearing marking shall pass the force
transmission testing when mounted in the The ISEA headform size 7 shall be used for the
reverse position on the headform.  force transmission test.

Type II Helmets that are to be marked with the
reverse wearing mark shall pass the force
transmission, impact attenuation, and off-center
penetration testing when mounted in the reverse
wearing position on the test headform.
7.3.2 High-Visibility
When measured in accordance with Section 9.8
of this standard, helmets marked “HV” for high-
visibility shall demonstrate chromaticity that lies
within one of the areas defined in Table 1 and
the total luminance factor (Y expressed as a
percentage) shall exceed the corresponding
minimum in Table 1.
For all other tests, any of three sizes of ISO
headforms described in ISO Standard ISO/DIS
6220 (See Figure 1) and specified by the
manufacturer shall be used. If headform size is
not specified by the manufacturer, the testing
facility is to decide the most suitable size.
8.1.2.1 Headform for Force Transmission
The headform used for the force transmission
test (Section 7.1.2) shall be the "ISEA standard
headform,” size 7 (approximate dimensions are
contained in Figure 3 for reference only). The
headform shall be made of low-resonance

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magnesium K-1A, or aluminum. The mass of the
headform shall be 3.64 kg ± 0.45 kg (8 lb ± 1 lb).
8.1.2.2 Headform for Penetration Tests
 
 A headform as specified in ISO/DIS 6220 and
made from electrically conductive material shall
be used for the apex penetration test (Section  
7.1.3) and the off-center penetration test
(Section 7.2.2) and shall be mounted on a ball
 joint so it can be pivoted into various positions.
8.1.2.3 Headform for Impact Energy
Attenuation Tests
 An ISO headform used for the impact energy
attenuation test (Section 7.2.1), shall be made of
a low resonance material such as cast silica
urethane, and have a Shore "D" durometer of 60
±
 6. The headform,
assemblies, together
shall have a masswith its supporting
of 5.0 kg ± 0.05
kg (11 lb ± 0.1 lb), with the center of gravity
roughly corresponding to the center of the
mounting ball.
8.1.3 Reference Test Lines
The static test line (STL) is established
according to the dimensions shown in Figure 11.
The dynamic test line (DTL) is established
according to the dimensions shown in Figure 2.
For the reverse wearing option, a separate DTL
shall be established according to the dimensions
shown in Figure 2 for the helmets in which the
test sample is mounted on the headform in the  
reverse wearing position.
8.1.4 Headform Mountings
Headforms used in conducting the force
transmission tests shall be mounted as shown in
Figure 3. Headforms used for impact energy
attenuation tests are mounted as shown in
Figure 4. Headforms used for penetration tests
are mounted as shown in Figure 5. Headforms
used for chin strap retention tests are mounted
as shown in Figure 6.
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8.2 Test Samples
8.2.1 Compliance Testing
A minimum of 30 test samples is required for
compliance testing in accordance with the
performance requirements of Section 7.
A minimum of 36 test samples is required for
compliance testing for helmets that are to be
marked for wearing in the reverse position.
It is not intended that the testing protocol
established in Table 3 be used for a
manufacturer’s quality assurance program.
8.2.2 Sequence of Testing
Testing shall be conducted in accordance with
the schedule outlined in Table 3. Some test
samples
one test. may be used
Helmets for performing
meeting more than
the requirements of
this standard are intended to provide protection
against only one blow (impact and/or
penetration). If a test sample fails to meet the
requirements of a given test (with the exception
of Class E electrical insulation test) and the
sample has previously been subjected to an
impact or penetration test, a new helmet shall be
tested to verify the "failing" result of that
particular test. Should the new helmet meet the
test requirements, then the "failing" result shall
be discounted.
8.2.3 Testing Conditions
All testing shall be performed at room
temperature 23°C ± 2°C (73.4°F ± 3.6°F). If
there is a disagreement in the test results
among different laboratories, the helmets shall
be re-tested at a controlled relative humidity of
50 ± 5 %.
8.3 Test Sample Markings
Test samples shall be marked to indicate the
location of STL and DTL. The largest size of
ISO headform appropriate for the helmet being
tested, whose circumference is not greater than
the internal circumference of the helmet
headband when adjusted to its largest setting,
shall be used. If no headband is provided, the
corresponding interior surface circumference of
the helmet shall be used to determine the
appropriate headform. Once the appropriate
reference headform is chosen, the test samples
shall be adjusted to provide a snug, but not tight,
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fit on the headform. All samples shall be
maintained at room temperature during marking.
8.3.1 Dynamic Test Line (DTL) Marking
Procedure
The headform shall be firmly seated with the
basic plane being horizontal. The test sample
shall be placed on the headform, centered
laterally oriented in the normal wearing position,
and seated firmly according to its positioning
index.
For samples that are marked to be worn in the
reverse position, the headband shall be installed
in the shell according to the manufacturer’s
wearing instructions for reverse donning. The
sample is then to be placed on the headform,
centered laterally, rotated 180 degrees from the
normal wearing position along the basic plane of
the headform, and seated firmly accordingly to
the manufacturer’s positioning index.
 A 50 N (11 lb) static force shall be applied
normal to the helmet's apex. Maintaining the
force and position described above, draw a line
on the outer surface of the helmet coinciding
with the intersections of the helmet surface and
the following planes, as defined in Figure 2:
(1) A plane "k" mm above and parallel to the
reference plane in the anterior portion of the  
reference headform.
(2) A vertical transverse plane "b" mm behind
the center of the central vertical axis in a side
view.
(3) A plane "j" mm above and parallel to the
reference plane in the posterior portion of the
reference headform.
One test line marked sample for normal wearing
and one marked sample for the reverse wearing
option should suffice for use in setting up the
subsequent testing.
8.3.2 Static Test Line (STL) Marking
Procedure
The headform shall be secured with the basic
plane being horizontal. The test sample shall be
placed on the headform, centered laterally,
leveled side-to-side and seated firmly according
to its positioning index. A 50 N (11 lb) static
force shall be applied normal to the helmet's
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apex. Maintaining the force and position
described above, draw a line on the outer
surface of the helmet coinciding with the
dimensions shown in Figure 11.
8.4 Helmet Preconditioning
8.4.1 Preconditioning Environments
Test samples shall be preconditioned prior to
performing the impact, penetration and chin
strap retention tests.
8.4.1.1 Hot
Test samples shall be placed in a forced air
circulating oven maintained at 49°C ± 2°C
(120°F ± 3.6°F) for at least two hours. No
sample shall be placed closer than 5 cm (2.0 in.)
to an internal
placed ovenand
horizontal wall. All specimens
in such a manner shall
as tobe
not block the flow of circulating air.
8.4.1.2 Cold
Test samples shall be placed in an
environmental chamber maintained at -18°C ± 
2°C (0°F ± 3.6°F) for at least two hours.
8.4.1.2.1 Lower Temperature (Optional)
As an optional alternative to cold preconditioning
at -18°C ± 2°C (0°F ± 3.6°F), lower temperature
preconditioning may be used. Test samples
shall be placed in an environmental chamber
maintained at –30°C ±2°C (-22°F ±3.6°F) for at
least four hours with the base of the helmet
facing upward (i.e., above the crown).
8.4.1.3 Wet
Test samples shall be submerged in fresh tap
water maintained at 23°C ± 2°C (73.4°F ± 3.6°F)
for at least two hours.
8.4.2 Testing Time
Hot-, cold- and lower temperature-conditioned
samples shall be tested for impact and
penetration within 30 seconds after their
removal from the conditioning environment.
Hot-, cold-, and lower temperature -conditioned
samples shall be tested for chin strap retention
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within 60 seconds after their removal from the
conditioning environment.
Wet samples shall be withdrawn from the water
bath and positioned upright and horizontal for a
maximum of 30 seconds to allow excess water
to drain. The wet samples shall then be
mounted on the applicable test apparatus and  
tested within 90 seconds from their removal of
the water bath.
9. Test Methods
9.1 Flammability
 
9.1.1 Preparation of Test Samples
Test samples shall be marked in accordance
with Section 8.3.2.
9.1.2 Apparatus
The test apparatus shall consist of the following
components:
 – laboratory test stand;
 – fume hood;
 – Bunsen burner (10 mm (0.4 in.) bore);
 – source of gas;
 – gas regulator;
 – timing device;  
 – temperature measurement device.  
The laboratory test stand shall be of sufficient  
size and strength to hold the test sample in an
as-worn, upright position (see Figure 12). The  
stand, including the attached test sample, shall
be placed inside a draft free fume hood.  
9.1.3 Calibration  
 A temperature measurement device shall be
used to verify the temperature of the Bunsen  
burner flame. With the Bunsen burner in a
vertical position, adjust it to produce a 50 mm
(2.0 in.) blue flame with an inner cone of 25 mm
(1.0 in.). Using the temperature probe, measure  
the temperature of the flame at the tip of the
inner cone. It shall be 800 – 900°C (1472 –
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1652°F). The use of natural methane
(laboratory grade) gas with a heat content of
1000 BTUs ± 100 BTUs per cubic foot is
recommended.
9.1.4 Test Procedures
Attach the test sample to the laboratory test
stand so that it is held in an as-worn, upright
position (see Figure 12). Choose any point on
the outer surface of the helmet above the STL
and apply the flame of the Bunsen burner such
that the tip of the inner cone is within 2 mm (0.08
in.) from the helmet surface. The Bunsen
burner shall be held with its barrel horizontal.
Apply the flame to the chosen test point for 5
seconds +1 second, -0 second, then remove the
flame. Inspect the test sample for any visible
flame 5 seconds after removal of the test flame.
9.1.5 Recording
Data recording is "pass" or "fail.”
9.2 Force Transmission
9.2.1 Preparation of Test Samples
Test samples shall be conditioned according to
Sections 8.4.1.1 and 8.4.1.2.
9.2.2 Apparatus 
The test apparatus shall consist of the following
components:
– test headform;
– headform mounting fixture;
– electronic load cell and velocity indicator;
– impactor;
– vertical drop guide mechanism;
– electronic signal conditioning and recording
equipment.
A typical test setup is shown in Figure 7. The
headform mounting fixture is shown in Figure 3.
Sources of equipment may be found in
Appendix E.
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The impactor shall have a mass of 3.60 kg ±  9.2.4 Calibration
0.05 kg (8 lb. ± 0.1 lb). The striking face of the
impactor shall be spherical with a radius of 4.8
cm ± 0.8 cm (1.9 in. ± 0.3 in.) and a minimum
chord length of 7.6 cm. (3.0 in.). The impactor
shall be constructed in such a manner that it will
remain rigid upon impact (single degree of
freedom system). The load cell system shall
conform to the following requirements:
 Accuracy = ± 2.5% Full Scale
Rigidity > 4.5 x 10 9 N/m (2.6 x 107 lb/ft)
Resonant Frequency = 5 kHz Min.
 A system known to work is detailed in Appendix
C.
The correctlybetween
be mounted mountedtheload cell assembly
headform shall
and a steel
plate at least 25 mm (1.0 in.) thick and at least
0.3 m (1 ft) square. The plate shall be bolted
down to, and in intimate contact with, a concrete
(or material of similar density) block that
measures approximately 1 x 1 x 0.3 m (3 x 3 x 1
ft). The plate shall be leveled with a precision
level to ± 1° of horizontal. The center of the
impactor, the center of the headform, and the
center of the load cell shall be co-linear as
measured by a plumb bob. The alignment
tolerance shall be 3 mm (0.12 in.).
9.2.3 Mounting
Where the crown clearance is adjustable, the
helmet shall be mounted with the least amount
of clearance.
The ISEA headform (as specified in Section 8.1)
shall be used. The test sample shall be
mounted with the STL horizontal and oriented in
its normal wearing position. The impactor shall
be aligned along the central vertical axis of the
headform.
For the samples to be tested in the reverse
wearing position, the headband is to be installed
in the shell according to the manufacturer’s
wearing instructions for reverse donning. The
sample is then to be placed on the headform  
with the STL horizontal, and rotated 180
degrees in the plane of the STL from the normal  
wearing position, and seated firmly accordingly
to the manufacturer’s positioning index.  
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The instrumentation shall be stabilized and
calibrated. A suggested method(s) for
calibration is included in Appendix C2. The
equipment shall be checked for repeatability
before and after each series of tests by
impacting a standardized elastomeric shock pad
as specified in the Appendix C3. A minimum of
three such impacts shall be recorded before and
after testing. If the post-test average readings of
the three impacts differ from the pre-test
average by more than 5%, the entire test series
shall be discarded.
9.2.5 Test Procedures
Test samples per Table 3, Schedule of Tests
shall be removed from the conditioning
environment
test headform(one at a time)
according and placed
to Section onThe
9.2.3. the
electronic recording device shall be zeroed after
a test sample is placed on the headform but
before the impact. The impactor shall be
dropped from a height that yields an impact
velocity of 5.50 m/s ± 0.05 m/s (18 ft/s ± 0.16
ft/s).
9.2.6 Recording
The individual maximum force readings for all
test samples shall be recorded along with the
impact velocities. The values for hot
conditioned test samples shall be averaged and
this result recorded. The values for cold
conditioned, or optionally low temperature test
samples shall be averaged and recorded.
9.3 Apex Penetration
9.3.1 Preparation of Test Samples
The test samples shall be conditioned according
to Section 8.4.1.1 and Section 8.4.1.2.
9.3.2 Apparatus
The test apparatus shall consist of the following
components:
– test headform;
– headform mounting fixture;
– electronic contact indicator and velocity
indicator;
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 – penetrator;
 – vertical drop guide mechanism;
 – electronic recording equipment.
 A typical test setup is shown in Figure 8. The
headform mounting fixture is shown in Figure 5.
The headform may be swiveled about the ball to
any position that would allow the penetrator to
strike the helmet perpendicularly anywhere
within a 75 mm (3.0 in.) diameter circle about
the apex of the helmet. The penetrator shall
have a mass of 1.0 kg ± 0.05 kg (2.2 lb. ± 0.1
lb.) with a steel tip, a 60° ± 1° included angle
and a spherical tip radius of 0.25 mm ± 0.10 mm
(0.010 in. ± 0.004 in.). A typical penetrator
configuration is shown in Figure 9.
The penetrator shall be constructed in such a
manner that it will remain rigid upon impact
(single degree of freedom system). The
penetrator shall be guided and electrically
insulated from the metal headform. The mass  
and size of the base shall be as specified in
Section 9.2.2. Wires shall be attached to the  
impactor and headform such that if the impactor
makes contact with the headform a low voltage  
electric circuit is completed. A suitable means
of verifying said completed circuit can be  
obtained by use of an oscillographic recording.
 
9.3.3 Mounting
The largest size headform (as specified in  
Section 8.1) appropriate for helmet being tested
shall be used. The helmet shall be mounted  
with the STL parallel with the basic plane of the
headform and with the axis of the penetrator
aligned with the center of the mounting ball of
the headform. 
9.3.4 Calibration
Before and after testing, contact of the
penetrator with the headform shall be made to
assure that the electric circuit, when completed,
is properly recorded by the recording device.
9.3.5 Test Procedures
Test samples per Table 3, Schedule of Tests
shall be removed from the conditioning
environment (one at a time) and placed on the
test headform according to Section 9.3.3. The
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impactor shall be dropped from a height that
yields an impact velocity of 7.0 m/s ± 0.1 m/s (23
ft/s ± 0.3 ft/s).
9.3.6 Recording
The impact velocity associated with each drop
shall be recorded. Data recording for
penetration is "pass" or "fail" based on any
indicated electrical contact.
9.4 Impact Energy Attenuation
9.4.1 Preparation of Test Samples
Test samples shall be marked according to
Section 8.3.1 and conditioned according to
Section 8.4.
9.4.2 Apparatus
The test apparatus shall consist of the following
components:
– test headform;
– vertical drop guide mechanism;
– uniaxial or triaxial accelerometer;
– hemispherical impact anvil;
– electronic signal conditioning and recording
instrumentation;
– velocity indicator.
A typical test setup is shown in Figure 10 and
the headform/vertical drop guide mechanism is
shown in Figure 4. Sources of equipment may
be found in Appendix E.
9.4.2.1 Mounting
The largest size test headform (as specified in
Section 8.1) appropriate to the helmet being
tested shall be used. The test shall be set up so
that the edge of the anvil does not extend below
the DTL line of the helmet. The headform shall
be mounted as required for the anvil to strike the
test sample anywhere above the DTL. The
center of the accelerometer mounting hole,
which will typically be the center of the headform
mounting ball, shall be in vertical alignment with
the center of the anvil within 10 mm (0.38 in.).
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The impact shall be as normal to the surface as
the contour of the shell will permit.
If there are projections on the helmet’s outer
surface above the DTL or internal projections
inside the helmet above the DTL, the helmet
shall be impacted directly on one of the
projections.
The test sample shall be mounted in its normal
wearing position on the headform with the STL
parallel to the basic plane of the headform.
For the samples to be tested in the reverse  
wearing position, the headband is to be installed
in the shell according to the manufacturer’s
wearing instructions for reverse donning. The
sample is then to be placed on the headform
with the STL parallel to the basic plane of the
headform, and rotated 180 degrees in the basic
plane from its normal wearing position, and  
seated firmly accordingly to the manufacturer’s
positioning index.
9.4.2.2 Impact Anvil
The impact anvil shall be constructed of steel.
The anvil shall be a spherical segment having a
radius of 4.8 cm ± 0.8 cm (1.9 in ± 0.3 in.) and a
chord length of 7.6 cm (3.0 in.). The test anvil
shall be rigidly mounted to a solid mass of at
least 135 kg (300 lb.) consisting of a steel plate
at least 25 mm (1.0 in.) thick and at least 0.3 m
(1 ft) square, bolted to and in intimate contact
with a concrete block (or equivalent).
9.4.2.3 Test Headform
The headform along with its associated vertical
drop guide mechanism shall have a mass of
5.00 kg ± 0.05 kg (11 lb. ± 0.1 lb.) and be
constructed in such a manner that it will remain
rigid upon impact (single degree of freedom
system). The headform supporting assembly
(vertical drop guide mechanism) shall not
exceed 25% of the mass of the total drop
assembly. The center of gravity of the total drop
assembly shall lie within a cone with its axis
vertical, a 10° included angle, and with the
vertex as the point of impact.
9.4.2.4  Accelerometer
The accelerometer is mounted at the
approximate center of gravity of the combined
test headform and vertical drop guide
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mechanism inside the headform mounting ball.
The axis of the uniaxial accelerometer, or the
vertical axes of a triaxial accelerometer, shall be
aligned within 2.5 degrees of vertical. The
accelerometer is connected to the signal
conditioning/recording instrumentation. The
acceleration data channels shall comply with the
Society of Automotive Engineers (SAE)
Recommended Practice J211 requirements for
channel class 1000. The accelerometer/
recording system shall conform to the following
requirements:
Accuracy = ± 2.5% Full Scale
Transverse Sensitivity = 3% max.
Resonant Frequency = 5 kHz min.
A
D.system known to work is detailed in Appendix
9.4.3 Calibration
The instrumentation shall be stabilized and
calibrated. A suggested method(s) for
calibration is included in Appendix D2. The
equipment shall be checked for repeatability
before and after each series of tests by
impacting a standardized elastomeric shock pad
as specified in the Appendix D3. A minimum of
three such impacts shall be recorded before and
after testing. If the post-test average readings of
the three impacts differ from the pre-test
average by more than 5%, the entire test series
shall be discarded.
9.4.4 Test Procedures
Test samples per Table 3, Schedule of Tests
shall be removed from the conditioning
environment (one at a time) and mounted on the
test headform according to Section 9.4.2.1. The
electronic recording device shall be zeroed after
a helmet is placed on the headform but before
the impact. The helmeted headform shall be
dropped from a height that yields an impact
velocity of 3.5 m/s ± 0.1 m/s (11.5 ft/s ± 0.3 ft/s)
as measured by the velocity indicator.
9.4.5  Recording
The maximum G value for each test shall be
recorded along with its associated impact
velocity.
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shall slide freely in the vertical direction within  
the test stand.
The drop mass (impactor) shall also slide freely
upon the pre-load assembly and shall have a
mass of 10.00 kg ± 0.05 kg (22.2 lb ± 0.1 lb).  
9.6.3 Calibration
 
The pre-load assembly and drop mass shall be
checked for freedom of movement before each
use.  
9.6.4 Test Procedures
The test samples per Table 3, Schedule of Tests
shall be mounted on the headform and the chin
strap threaded around the stirrup while the drop
mass shall be held such that it does not interfere
with the pre-load
be adjusted assembly.
so that the stirrupThe chinare
rollers strap shall
approximately in line with the pre-load
adjustment point specified in Figure 6. The
deflection scale shall be zeroed with the 1.5 kg
(3.3 lb) pre-load assembly in place. The drop
mass shall be dropped onto the pre-load
assembly from 10.0 cm ± 0.5 cm (4.0 in. ± 0.2
in.). A deflection reading shall be taken neither
less than 15 nor more than 30 seconds after
impact.
9.6.5 Recording
The deflection (elongation) value shall be
recorded for each test sample.
9.7 Electrical Insulation
9.7.1 Preparation of Test Samples
Test samples tested for Class E requirements
shall first be subjected to the force transmission
test, one conditioned hot and one conditioned
cold.
9.7.2 Apparatus
The test apparatus shall consist of the following
components:
 – a vessel containing fresh tap water, of  leakage shall be recorded.
sufficient size to immerse the inverted helmet to
the water line;
 – a frame for suspending the test sample in the
water;
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– a source of 60-Hertz alternating current
variable from 0 to 30,000 volts (root mean
square voltage) with at least a 20-milliampere
capability at 20,000 volts;
– wiring and terminals for application of voltage
across the crown of the test sample;
– a voltmeter of sufficient capacity to measure
the specified voltages;
– a suitable milliammeter of sufficient capacity
and accuracy to measure the specified currents.
9.7.3 Calibration
Voltmeters and milliammeters shall be in
calibration.
9.7.4 Test Procedures
(See Section 8.3.2) Permanently attached
helmet accessories (including welding helmet
brackets, lamp brackets, chin straps, etc.) shall
be retained on the test samples during testing.
Non-removable chin straps shall be positioned
such that they do not complete the electrical
circuit or otherwise interfere with the test.
9.7.4.1 Class G Testing
While holding the test sample in the inverted
position, it shall be filled with fresh tap water up
to the STL; unless the helmet contains holes in
the crown for mounting the suspension, in which
case it shall be filled to 12.7 mm (0.5 in.) of
those holes. No special provisions shall be
made for any accessory mounting holes above
the plane of the suspension mounting holes.
The test sample shall then be submerged in the
same type of water and to the same level as the
water on the inside of the helmet. The voltmeter
and the milliammeter shall be attached to the
circuit. Care shall be taken to keep the
unsubmerged portion of the test sample dry so
that flash over will not occur when voltage is
applied.
The voltage shall be applied, increased to 2200
volts, and held for one minute. The current
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9.7.4.2 Class E Testing 2) use illumination D65 and 45/0 or 0/45

 As with Class G testing, the inside of the test
sample shall be filled with fresh tap water up to
the STL, or to a lower level but no lower than is
required to prevent flash over at the test voltage.
The test sample shall then be immersed in the
same type of water and to the same level as the
water on the inside of the test sample. The
voltmeter and milliammeter shall be attached to
the circuit.  
Care shall be taken to keep the unsubmerged
portion of the test sample dry so that flash over  
will not occur when voltage is applied. The
voltage shall be applied, increased to 20,000
volts, and held for three minutes. The current
leakage shall be recorded.
 
The test sample shall then be tested for burn-
through by further increasing the voltage to
30,000 at the rate of 1000 volts per second and
then immediately reducing the voltage to zero.
9.7.5 Recording
geometry with 2° standard observer and a black
underlay with a reflectance of less than 0.04.
10. Normative References
The following standards contain provisions that,
through reference in this text, constitute
provisions of this American National Standard.
At the time of publication, the editions indicated
were valid. All standards are subject to revision,
and parties to agreements based on this
American National Standard are encouraged to
investigate the possibility of applying the most
recent editions of the standards indicated below:
ASTM E1164–02 Colorimetry - Standard
Practice for Obtaining Spectrophotometric Data
for Object-Color Evaluation  
ISO/DIS 6220-1983, International Standard -
Headforms for Use in the Testing of Protective
Helmets  

For each test sample, the leakage current SAE J 211-1, 2007, Instrumentation for Impact
and/or any evidence of burn-through shall be Test, Part 1, Electronic Instrumentation  
recorded.

9.8 High-Visibility Testing

9.8.1 Sampling and Conditioning

One test plaque shall be tested. The test plaque
shall be conditioned for at least 24 hours at 20 ±
2°C (68 ± 2 °F) and 65 ± 5 % relative humidity.
If testing is carried out in other conditions, the
test shall be conducted within 5 minutes after
withdrawal from the conditioning atmosphere.

9.8.1 Determination of Color

The color shall be measured in accordance with

the procedures defined in ASTM E1164–02
Colorimetry - Standard Practice for Obtaining
Spectrophotometric Data for Object-Color
Evaluation  with the following conditions:

1) set the spectrophotometer at a wavelength

range of 400-700 nm and at intervals of 10 nm
as stated in paragraph 7.3.1.2 of ASTM E1164;
and

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Table 2 – Sizing Chart 

CIRCUMFERENCE
HAT SIZE
Centimeters Inches
6-1/2 52 20-1/2
6-5/8 53 20-7/8
6-3/4 54 21-1/4
6-7/8 55 21-5/8
7 56 22
7-1/8 57 22-3/8
7-1/4 58 22-3/4
7-3/8 59 23-1/8
7-1/2 60 23-1/2
7-5/8 61 23-7/8
7-3/4 62 24-1/4
7-7/8 63 24-5/8
8 64 25
8-1/8 65 25-3/8
8-1/4 66 25-3/4
8-3/8 67 26-1/8
8-1/2 68 26-1/2

Note: This table is intended for sizing guidance of round head bands only and should not be construed as
prohibiting larger or smaller headbands.

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Table 3 – Schedule of Tests

Minimum Test
Test Method Number Sample Test Sequence by Helmet Type & Class
Of Numbers IG IE IC IIG IIE IIC
Samples

9.1 Flammability 1 12 4 4 3 7 7 6

9.2 Force Transmission

Hot 12 1-12 2 1 1 2 1 1
Cold or Lower Temperature 12 13-24

9.2 Force Transmission (reverse

wearing)

Hot 31-33 3 2 1 1 2 1 1
Cold or Lower Temperature 34-36 3
9.3 Apex Penetration

Hot 3 25-27 3 3 2 3 3 2
Cold or Lower Temperature 3 28-30
9.4 Impact Energy Attenuation

Hot 4 2-5
Cold or Lower Temperature 4 14-17 4 4 3
Wet 4 6,7,18,19
9.4 Impact Energy Attenuation
(reverse wearing)

Hot 31 1 2 1 1
Cold or Lower Temperature 32 1
Wet 34 1
9.5 Off Center Penetration

Hot
Cold or Lower Temperature 2
2 8,9
20,21 5 5 4
Wet 2 10,22
9.4 Off Center Penetration
(reverse wearing)

Hot 33 1 2 1 1
Cold or Lower Temperature 35 1
Wet 36 1
9.6 Chin Strap Retention

Hot 1 11
Cold or Lower Temperature 1 13 6 6 5
Wet 1 23
9.7 Electrical Insulation

a) 2.2 KV Type I 2 1, 13 1
b) 20 KV Type I 2 1, 13 2
a) 2.2 KV Type II 2 1, 24 1
b) 20 KV Type II 2 1, 24 2

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Schedule of tests

Type I, Class G Helmets

Sample numbers 1 and 13 should be used for the electrical insulation test. Next, sample numbers 1–24
should be subjected to the force transmission test. Sample numbers 25-30 should be subjected to the
apex penetration test. The flammability test should be performed using sample number 12.

Type I, Class E Helmets

Sample numbers 1–24 should be subjected to the force transmission test. Sample numbers 1 and 13
should then be used for the electrical insulation test. Sample numbers 25-30 should be subjected to the
apex penetration test. The flammability test should be performed using sample number 12.

Type I, Class C Helmets

Type I, Class C helmets should be tested similarly to Type I, Class G and Type I, Class E helmets except
the electrical insulation tests are not performed.

Type II, Class G Helmets

Sample numbers 1 and 24 should be used for the electrical insulation test. Next, sample numbers 1–24
should be subjected to the force transmission test. Sample numbers 25-30 should be subjected to the
apex penetration test. Next, sample numbers 2-7 and 14-19 should be subjected to the impact energy
attenuation test.

Sample numbers 8-10 and 20-22 should then be subjected to the off-center penetration test.

If the helmet is provided with a chin strap, then sample numbers 11, 13 and 23 should be used to perform
the chin strap retention test.

The flammability test should be performed on sample number 12.

Type II, Class E Helmets

Type II, Class E helmets should be tested similarly to Type II, Class G helmets except test samples 1 and
24 should be subjected to the force transmission test before conducting the electrical insulation test
instead of after the electrical insulation test.

Type II, Class C Helmets

Type II, Class C helmets should be tested similarly to Type II, Class G and Type II, Class E helmets
except the electrical insulation tests are not performed.

Reverse Wearing for Type I and Type II Helmets

Sample numbers 31–36 should be subjected to the force transmission test in the reverse wearing
position. Samples numbers 31, 32, and 34 should then be subjected to the impact energy attenuation
test and samples numbers 33, 35, and 36 should be subjected to the off-center penetration testing in the
reverse wearing mounting position.

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Figure 1 –ISO Headform

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Figure 2 – Dynamic Test Line (DTL)

Impact and Penetration Tests

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Dimensions are approximate

Figure 3 – Force Transmission Headform 

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Figure 4 – Typical Impact Energy Attenuation Headform Fixture

(all dimensions for reference only)

Figure 5 – Typical Penetration Headform Fixture

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Figure 7 – Typical Force Transmission Test Apparatus

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Figure 8 – Typical Penetration Test Apparatus

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Figure 9 – Typical Penetrator  

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Figure 10 – Typical Impact Energy Attenuation Test Apparatus

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Figure 11 – Static Test Line (STL)

Electrical Insulation and Flammability Tests

Figure 12 – Flammability Test Apparatus  

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Appendices
The following appendices not part of American National Standard ANSI/ISEA Z89.1-2009, but are
included for information only. 

Appendix A
Recommendations, Cautions, Use, and Care

A1. Instructions and Warnings

 All instructions, warnings, precautions and limitations given by the manufacturer should always be
transmitted to the wearer and care should be taken to see that such precautions and limitations are
strictly observed. Helmets whose markings (as defined in Section 6.2 of this standard) are missing or
obliterated should not be used.

A2. Fitting

Some helmets are designed to fit one size while others are adjustable. Follow the manufacturer’s
instructions for proper fitting procedures.

A3. Cleaning 

Shells should be cleaned following the manufacturer’s instructions. The helmet should be carefully
inspected for any signs of damage.

A4. Painting

Caution should be exercised if shells are to be painted, since some paints and thinners may attack and
damage the shell and reduce protection. The helmet manufacturer should be consulted with regard to
paints or cleaning materials.

A5. Inspection
 All components and accessories, if any, should be visually inspected prior to each use for signs of dents,
cracks, penetration, and any damage due to impact, rough treatment, or wear that might reduce the
degree of protection originally provided. A helmet with worn, damaged or defective parts should be
removed from service.

A6. Limitation of Protection

Users are cautioned that if unusual conditions prevail (for example, higher or lower extremes of
temperature than those described), or if there are signs of abuse of or damage to the helmet or of any
component, the degree of protection may be reduced. Any helmet that has received an impact should be
removed from service, since the impact may have substantially reduced the protection offered.

NOTE: Certain materials are susceptible to damage from ultraviolet light and chemical degradation, and
helmets are no exception. Periodic examinations should be made of all protective helmets and, in
particular, those worn or stored in areas exposed to sunlight for long periods. Ultraviolet degradation
may first manifest itself in a loss of surface gloss, called chalking or discoloration. Upon further
degradation, the surface will craze or flake away, or both. At the first appearance of any of these
phenomena, the shell should be replaced.

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A7. Precautions 

Because helmets can be damaged, they should not be abused. They should be kept free from abrasions,
scrapes, and nicks and should not be dropped, thrown, or used as supports. This applies especially to
helmets that are intended to afford protection against electrical hazards.

Industrial protective helmets should not be stored or carried on the rear window shelf of an automobile,
since sunlight and extreme heat may cause degradation that will adversely affect the degree of protection
they provide. Also, in the case of an emergency stop or accident, the helmet might become a hazardous
impactor.

Users should exercise extreme care in the selection and installation of accessories. The addition of
accessories to the helmet may adversely affect the level of protection. The user should make sure that
any accessory is compatible with the helmet. Contact the helmet or accessory manufacturer for
compatibility information.

Users should never alter or modify the helmet (e.g. drill, glue, cut, etc.) to accept accessories unless
instructed to do so by the helmet manufacturer. Helmet decorations should not be used to obscure
dents, cracks, non-manufactured holes, other penetrations, burns or other damages.
Caution should be taken when marking or decorating Class G or E helmets. Identification markers used
on shells for helmets meeting Class G or E requirements shall be affixed without making holes through
the shell and without the use of any metal parts. Metallic based markers such as some reflective tapes,
metal foil labels or metal foil hot stamps should be applied only with the helmet manufacturer's
authorization.

A8. Safe Conditions

Neither the impact/penetration requirements nor the electrical insulation requirements should be
construed to indicate the safe impact level or safe voltage to which the industrial worker may be
subjected. The maximum voltage against which helmets will protect the wearer depends on a number of
variable factors, such as the characteristics of the electrical circuit and the equipment involved, the care
exercised in maintenance of equipment, and weather conditions. Therefore, the safe and proper use of
helmets is beyond the scope of this standard.

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Appendix B
Electrical Insulation Testing

B1. Equipment Guidelines

Commercially available high-voltage test equipment can provide self-contained voltage and current-
sensing circuits with adjustable current limiting from 3 to 30 milliamperes. With these units, all that is
required is a test stand for the helmet and appropriate safety interlocks. The transformer should have a
rating of at least 400 volt-amperes and have one side of the high-voltage supply grounded.

If a multi-station test stand is to be used to test more than one helmet at a time, an additional current
meter should be added for each helmet being tested. The volt-ampere rating of the transformer should
be increased about 350 volt-amperes for each additional station.

 A multi-station test stand can also be built so that the external tank is charged and the inside of each
helmet can be alternately grounded through a suitable current meter. With this arrangement, only one
meter is required. It does not have to be protected from high voltage, and no increase in the transformer
rating is necessary.

B2. Precautions

High-voltage test equipment is inherently dangerous because of the relatively high volt-ampere rating of
the transformer and its stored energy capacity that can produce a current in excess of the current limit
that has been set for a fraction of a second. People familiar with the relatively harmless automotive
ignition and other small (although high-voltage) coils may have developed a false sense of security. The
following checklist is submitted to supplement those of the equipment manufacturers and the testers, and
should not be considered a complete list of safety precautions.

(1) Prepare and review the test procedure during an operator's training. Post the procedure on
the test stand. Only well-trained and competent personnel should operate this equipment.

(2) Post "High Voltage" signs in the area and equip the system with vivid pilot lights to indicate
that it is operating.

(3) Ground the system.

(4) Contain the helmet under test in an insulated chamber of Plexiglas or a similar material, with
safety interlocks on the door. The interlocks should be fail-safe and operated with low voltage, such as
24 volts. All joints and openings in the chamber should have grounded screen or wires over or adjacent
to them on the inside of the chamber. Maintenance of this ground and the ground mentioned in item (3)
should be part of the safety interlock system.

(5) Provide dual hand contacts to occupy both hands of the operator.

(6) Do not allow other people in the area during testing.

(7) Do not allow moisture or water to accumulate during or after testing. Ozone is generated
during the testing, and may be dangerous. Ozone may be radioactive and may induce or worsen
respiratory tract diseases of viral or microbial origin. A small cage-type fan can be used to extract ozone
from the test chamber, with an airflow from vents at the end of the chamber furthest from the point of
extraction. The ozone should be vented to the outside or absorbed in a bromide or iodide solution.

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Appendix C
Force Transmission Testing 

C1. Equipment Guidelines

The impact tester should have a guidance system at least three meters in height and capable of
producing impact velocities required by this standard. Test anvils, headforms, transducers, etc., mounted
to the base should be attached so that no energy is absorbed through deflections and the base should be
at least 25 mm (1.0 in.) thick steel. Friction between the falling carriage and the guidance system should
be minimized by the use of suitable bearing materials. The impactor guide mechanism should contain an
automatic brake to prevent second impacts (bouncing). A velocity detector is required to assure proper
drop heights. The position of said detector should be adjustable so that the speed of impact is measured
no more than 2.0 cm (0.79 in.) from the point of impact. A detector flag attached to the guide mechanism
which passes through or by the detector should not be greater than 26 mm (1.02 in.) height. The detector
should be capable of resolving velocities of 0.01 millisecond increments. The photo beam, visible,
infrared, etc., should have emitter/receiver slots no greater than 0.05 mm (0.002 in.) running normal to
the path of travel of the flag. Magnetic detector systems may also be used if equivalency is established.
 An electronic timer is used to determine the speed at which the flag traverses the detector. The load cell
should conform to the following characteristics:
Size 75 mm diameter. (3.0 in.) Min.
Measuring Range 0-5000 N (1124 lb) Min.
Resolution 45 N (10.1 lb) Max.
 Accuracy, Linearity ± 2.5% Full-scale Max.
Rigidity 4.5 x 109 N/m (2.6 x 10 7 lb/in.) Min.
Transverse Sensitivity 3.0% Max.

The resonant frequency of the load cell/headform assembly should not be less than 5 kHz, and the
frequency response of the system should be in compliance with SEA Recommended Practice J211,
Channel Class 1000.

It is recommended that the load cell output be recorded with a storage oscilloscope, transient recorder or
similar device designed to store maximum readings. However, maximum force readings may be
obtained using a peak indicating meter designed to store only a maximum reading. The frequency
response of peak indicating meters should at least meet the requirements of SEA Recommended
Practice J211, Channel Class 1000. Resolution should be 45 N (10.1 lb) Max. with rise time capability
less than 0.01 milliseconds.

C2. Calibration

Strain gauge type load cells can generally be calibrated staticly by applying a known dead weight to the
top of the load cell and checking the output signal. This works well with an oscilloscope or voltmeter.
However, transient vibrations tend to create a problem when using peak indicating meters, and thus the
load shall be applied and/or removed with extreme care. Furthermore, static calibration does not take
into account the dynamic response of the measuring system. Dynamic calibration is recommended but
requires a calibrated reference accelerometer and a calibrating medium (shock pad). The reference
accelerometer should have the following characteristics:

Measuring Range 0-400 G's Min.

Resolution 1.0 G Max.
 Accuracy, Linearity 1.0% Full-scale Max.
Transverse Sensitivity 3.0% Max.
Resonant Frequency 20 kHz Min.
Frequency Response   ± 0.5 dB @ 0.1 Hz - 2 kHz

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Repeatability/Stability 1.0% Full-scale Max.

The calibrating medium should have the following characteristics:

Material Elastomer (High Resilience and Low Hysteresis)

Durometer 50-60 Shore A
Thickness 25 mm (1.0 in.) Minimum
Size 100 mm (4.0 in.) Diameter Minimum

The accelerometer is mounted on top of the 3.6 kg (8.0 lb) impactor along its vertical axis (± 2.5o of true
vertical) according to the manufacturer's instructions. A dual channel storage oscilloscope is
recommended for making simultaneous recordings of both accelerometer and load cell outputs. Both
accelerometer and oscilloscope should be in recent calibration.

Force Measuring System Calibration Procedure

Remove headform from load cell and mount the calibrating medium to the top of the load cell. All
electronic systems should be turned on and allowed to stabilize. The impactor, with accelerometer
attached, should be dropped onto the calibrating medium from a height which yields a maximum
acceleration reading of 100 ± 10 Gs. Outputs of both accelerometer and load cell should be recorded.
The two maximum values should read within 2.5% of each other according to F =ma (Force = Mass x
 Acceleration). This degree of accuracy shall be repeatable through at least five impacts.

Velocity Measuring System Calibration Procedure 

If a simulated detector flag (ball) cannot be dropped in "free fall" from a known height through or by the
detector, the velocity measuring system should be returned to the manufacturer at least every six months
for re-calibration. Otherwise, a ball of known diameter can be dropped from a known height to trigger the
velocity detector. The ball shall be large enough to properly trigger the detector and have enough mass
to negate the effects of aerodynamic friction. The ball should be dropped from at least one meter. The
actual velocity is then calculated from:

 ____
V = 2gh

Where g = Gravitational Constant and h = Drop Height. This value is then compared to the measured
velocity. Both values should agree within 1.0%.

C3. System Repeatability Procedure

With the calibrating medium (shock pad) described in Appendix C2 mounted to the top of the load cell,
three consecutive drops of the impactor onto the medium should be made. The velocity of impact should
be maintained at 4.0 m/s. ± 0.03 m/s (13.1 ft/s ± 0.1 ft/s). The repeatability value should be the average
of the three maximum transmitted force readings. The total range for the three values should not exceed
± 5.0% of the average value.

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Appendix D
Impact Energy Attenuation Testing

D1. Equipment Guidelines

The impact tester should have a guidance system at least 2.0 m (6.6 ft) in height to produce impact
velocities required for this standard. The test anvils (flat and hemispherical) should be made to be
interchangeable on the base and be attached so that no energy is absorbed through deflections and the
base should be at least 25 mm (1.0 in.) thick steel. Friction between the falling carriage and the guidance
system should be minimized by the use of suitable bearing materials. A velocity detector is required to
assure proper drop heights. The position of said detector should be adjustable so that the speed of
impact is measured no more than 2.0 cm (0.79 in.) from the point of impact. A detector flag attached to
the guide mechanism that passes through or by the detector should not be greater than 26 mm (1.02 in.)
in height. The detector should be capable of having a resolution no greater than 0.01 milliseconds. The
photo beam, visible, infrared, etc., should have emitter/receiver slots no greater than 0.05 mm (0.002 in.)
running normal to the path of travel of the flag. Magnetic detector systems may also be used if
equivalency is established. An electronic timer is used to determine the speed at which the flag traverses
the detector. Attached to the guide mechanism, in such a way as to prevent rotation, should be a
mounting ball. Test headforms are mounted on said ball with a clamping ring such that the headforms
may be swiveled about the ball. An accelerometer should be mounted inside the ball, having its axis (or
the vertical axes, in the case of a triaxial accelerometer) within 2.5 degrees of vertical alignment.

The accelerometer should conform to the following characteristics:

Shape Cubic, with Flat Sides

Size 25 mm (1.0 in.) Max. Dimensions
Measuring Range 0-500 G's Min.
Resolution 1.0 G Max.
 Accuracy, Linearity 1.0% Full-scale Max.
Transverse Sensitivity 5.0% Max.
Resonant Frequency 20 kHz Min.
Frequency Response ± 5 dB @ 0.1 Hz - 2 kHz
Repeatability/Stability 1.0% Full-scale Max.

The frequency response of the system should be in compliance with SEA Recommended Practice J211-
1, Channel Class 1000. Each channel resolution should be 1.0 G Max. with rise time capability less than
0.01 milliseconds.

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D2. Calibration

While there are several acceptable methods of accelerometer calibration, one method may be performed
using the fixture specified in Appendix C2 for dynamic calibration. In this case, however, the calibrated
reference accelerometer and the test accelerometer should be fixed in "piggyback" fashion, one on top of
the other. The cubic shaped test accelerometer lends itself well to this procedure. The axis should be in
vertical alignment with the axis of the reference accelerometer and the vertical axis of the impactor.
Practice has demonstrated that thin, "double stick" tape can be used to fixture the accelerometers, one
on top of the other. This assumes that the flat surface of the accelerometers in contact with the tape is at
least 50 square mm (2.0 square in.) and that the cables are properly tied down and held in place.

Acceleration Measuring Procedure

Remove the test accelerometer from the mounting ball. Mount this unit on the impactor then mount the
calibrated reference accelerometer on top of the test accelerometer. Mount the calibrating medium as in
 Appendix C2. All electronic systems should be turned on and allowed to stabilize. The impactor, with
accelerometers attached, should be dropped onto the calibrating medium from a height which yields a
maximum acceleration, as indicated by the reference accelerometer of 200 ± 20 Gs. The vertical axis
outputs of both accelerometers should be recorded. The two maximum values should read within 2.0%
of each other. This degree of accuracy should be repeatable through at least five impacts.

Velocity Measuring System Calibration Procedure

For checking the calibration of velocity detectors, see Appendix C2.

D3. System Repeatability Procedure

Mount the calibrating medium (shock pad) described in Appendix C2 onto the test base in place of the
test anvil(s). Position the headform inverted, with the basic plane horizontal. With the accelerometer
connected to the recording/computing instrumentation, three consecutive drops of the headform onto the
medium should be made. The velocity of the impact should be maintained at 3.0 m/s ± 0.03 m/s (9.8 ft/s
± 0.1 ft/s). For each drop a Maximum G value should be recorded. The repeatability value should be the
average of the three measurements. However, the total range for all three values should not exceed ± 
5.0% of the average value.

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Appendix E
Test Equipment Sources 

Many sources can provide suitable test equipment. Below is a partial listing:

Impact/Penetration Monorail Test Kistler Instrument Corporation SGS U.S. Testing Company, Inc.
Stands 75 John Glenn Drive 291 Fairfield Avenue
 Amherst, NY 14120-5091 Fairfield, NJ 07004-3885
SGS U.S. Testing Company, Inc. (P) 888-547-8537 (P) 973-575-5252
291 Fairfield Avenue (F) 716-691-5226 (F) 973-575-7157
Fairfield, NJ 07004-3885 www.kistler.com www.ustesting.sgsna.com
(P) 973-575-5252
(F) 973-575-7157 Accelerometers Calibrating Medium
www.ustesting.sgsna.com
PCB Piezotronics, Inc. MTS Systems Corporation
ISO Headforms 3425 Walden Avenue 14000 Technology Drive
Depew, NY 14043-2495 Eden Prairie, MN 55344-2290
Biokinetics and Associates Ltd. (P) 716-684-0001 (P) 952-937-4000

2470 Don Reid Drive (F) 716-684-0987 (F) 952-937-4515

Ottawa, Ontario K1H 1E1 www.pcb.com www.mts.com
CANADA
(P) 613-736-0384 Kistler Instrument Corporation SGS U.S. Testing Company, Inc.
(F) 613-736-0950 75 John Glenn Drive 291 Fairfield Avenue
www.biokenetics.com  Amherst, NY 14120-5091 Fairfield, NJ 07004-3885
(P) 888-547-8537 (P) 973-575-5252
CADEX Inc. (F) 716-691-5226 (F) 973-575-7157
175 Rue St. Paul www.kistler.com www.ustesting.sgsna.com
St. Jean-Sur Richelieu
Quebec, CANADA J3B 8N7 Endevco Corporation Data Acquisition/Computer
(P) 450-348-6774 30700 Rancho Vieto Road Systems
www.cadex.com San Juan Capistrano, CA 92875
(P) 800-982-6732 GHI Systems, Inc.
ISEA Headform www.endevco.com 916 N. Western Avenue
San Pedro, CA 90732
Inspec Laboratories Ltd. Entran Devices, Inc. (P) 800-GHI-SYST
56 Leslie Hough Way 10 Washington Avenue (F) 310-548-5749
Salford, Greater Manchester M6 6AJ Fairfield, NJ 07004 www.ghisys.com
UNITED KINGDOM (P) 973-227-1002
(P) 44 (0) 16 17 37 06 99 (F) 973-227-6865
(P) 44 (0) 16 17 36 01 01 www.entran.com

Load Cells Velocity Detectors

SGS U.S. Testing Company, Inc. GHI Systems, Inc.

291 Fairfield Avenue 916 N. Western Avenue
Fairfield, NJ 07004-3885 San Pedro, CA 90732
(P) 973-575-5252 (P) 800-GHI-SYST
(F) 973-575-7157 (F) 310-548-5749
www.ustesting.sgsna.com www.ghisys.com

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