ANSI-IsEA Z89.1 (2009) - American National Standard for Industrial Head Protection

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A N S I / I S E A Z89.1-2009

American National Standard

for Industrial Head Protection



ANSI/ISEA Z89.1-2009

Revision ofANSI Z89.1-2003

American National Standard for Industrial Head Protection

Secretariat

International Safety Equipment Association

Approved January 26, 2009

American National Standards Institute, Inc.



AmericanNationalStandard

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CAUTION NOTICE: This American National Standard may be revised orwithdrawn at any time. The procedures of the American National StandardsInstitute require that action be taken to reaffirm, revise, or withdraw this standardno later than five years from the date of publication. Purchasers of AmericanNational Standards may receive current information on all standards by calling orwriting the American National Standards Institute.

Published by

International Safety Equipment Association1901 North Moore Street, Suite 808, Arlington, Virginia 22209

Copyright © 2009 by International Safety Equipment AssociationAll rights reserved.

No part of this publication may be reproduced in anyform, in an electronic retrieval system or otherwise, withoutthe prior written permission of the publisher.

Printed in the United States of America



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

Voluntary industry consensus standards recognized by the American National Standards Institute arerequired to be reviewed every five years to account for improvements in technology, test methods andmaterials, user needs and trends in use and application of products covered under the respective

standard. This sixth revision of the American National Standard for Industrial Head Protection, ANSI/ISEA Z89.1-2009 represents an effort to accommodate characteristics of industrial headprotection that end-users identified as being important as work environments change and emerginghazards are identified. This 2009 edition was prepared by the ISEA Head Protection Group whosecurrent members include: 3M Company, Bullard, ERB Industries, Gateway Safety, Jackson Safety,MSA, North by Honeywell, OccuNomix International, Sellstrom Manufacturing Co., and SperianProtection.

This version of ANSI/ISEA Z89.1-2009 incorporates optional testing and marking features for headprotection devices. Notable among these are specific testing protocols and marking for products thathave high-visibility properties. Criteria for these products are based on well-established test methodsfound in other industry standards. Additionally, criteria have been incorporated for products that can beworn 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 theapproval of this standard. Inclusion in this list does not necessarily imply that the organizationconcurred with the submittal of the proposed standard to ANSI.

APM Terminals Intertek Testing Services Atlas Industrial Contractors National Personal Protective Technologies LaboratoryCity of San Diego Parsons BrinckerhoffEntergy Services Incorporated Safety Equipment InstituteICS 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

[email protected]



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



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 ...................................................................... 206. 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 ...................................................A1B. 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 Standardfor Industrial Head Protection

1. Scope, Purpose and Limitations

1.1 Scope

This standard describes Types and Classes,testing and performance requirements forprotective helmets. These includerecommended safety requirements forauthorities considering the establishment ofregulations or codes concerning the use ofprotective helmets.

1.2 Purpose

This standard establishes minimum

performance requirements for protectivehelmets that reduce the forces of impact andpenetration and that may provide protectionfrom electric shock.

1.3 Limitations

Protective helmets reduce the amount of forcefrom an impact blow but cannot providecomplete head protection from severe impactand penetration. Helmets that meet thisstandard provide limited protection but shouldbe effective against small tools, small pieces of

wood, bolts, nuts, rivets, sparks and similarhazards. The use of protective helmets shouldnever be viewed as a substitute for good safetypractices and engineering controls. Alterations,attachments, or additions of accessories mayaffect the performance of the helmet. Helmetsare designed to provide protection above thetest lines, which are clearly defined in thestandard. Helmets may extend below the testlines for styling or practical purposes but noprotection is to be implied below the test lines.

2. Compliance

Any statement(s) of compliance with thisstandard shall mean that the product meets allapplicable requirements for the Type and Class.It is specifically intended that partial utilization ofthis standard is prohibited.

3. Definitions

accessory: A device intended to be mountedon or used with protective helmets. (See Section5)

apex: The point on the outer surface of theshell coincident with the vertical axis of theheadform when mounted in the as-worn positionaccording to the manufacturer's instructions.

basic plane: A plane at the level of the externalauditory meatus (external ear opening) and theinferior margin of the orbit (lower edge of theeye socket).

brim: An integral part of a helmet shellextending outward around the entirecircumference of the lower shell.

chin strap: A strap which fits under the chinand is attached to the helmet.

crown straps: The part of the suspension thatpasses over the head.

dynamic test line (DTL): A test line used as aboundary for conducting impact energy

attenuation and off-center penetration tests.

flammability: The ability of a helmet shell tosupport combustion upon removal of the testflame.

harness: The complete assembly used tomaintain a helmet in correct wearing position onthe wearer's head, exclusive of a chin strap orother retention device.

headband: The part of the harness thatencircles the head.

helmet: A device worn on the head designed toprovide limited protection against impact, flyingparticles or electric shock.

manufacturer: The business entity that marksor directs the permanent marking of thecomponents or complete device as compliantwith this standard and sells them as compliant.




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midsagittal plane: A longitudinal plane,perpendicular to the basic plane, which passesthrough the vertex and geometrically bisects thehead.

nape strap: A strap that fits behind the headbelow the reference plane.

peak: A part of the shell extending forward overthe wearer's forehead.

positioning index: A perpendicular distance,as specified by the manufacturer, from somepoint on the helmet to the basic plane when thehelmet is properly seated on a referenceheadform.

projection: Rigid features that extend orprotrude beyond the normal internal or external

surface or contour of the helmet.

protective padding: Any material used toabsorb the kinetic energy of impact.

reference plane: A plane at a given distanceabove and parallel to the basic plane.

reference headform: A measuring devicecontoured to specified dimensions with surfacemarkings indicating the locations of the basic,midsagittal and reference planes, as well as anyrequired test lines.

shall: In this standard, use of the word "shall"indicates a mandatory requirement.

shell: The part of a helmet which includes theoutermost surface.

should: In this standard, use of the word"should" indicates a recommendation.

suspension: The portion of the harness whichis designed to act as an energy-absorbingmechanism. It may consist of crown straps,

protective padding, or a similar mechanism.

static test line (STL): A test line used as aboundary for conducting electrical insulation,flammability tests and for mounting for the forcetransmission test.

test line: A line or combination of lines markedon a reference headform used to provide limitsor a boundary beyond which protection is notconsidered.

test plaque: A sample of the helmet orrepresentative shell material with a thickness of3 mm ± 0.5 mm.

4. Types and Classes

Protective helmets are described by impact typeand electrical class. All protective helmets shallmeet either Type I or Type II requirements. Allhelmets shall be further classified as meetingClass G, Class E, or Class C electricalrequirements. Helmets meeting the reversewearing testing requirements shall be markedwith 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 forceof impact resulting from a blow only to the top ofthe head.

4.1.2 Type II

Type II helmets are intended to reduce the forceof impact resulting from a blow to the top orsides of the head.

4.2 Electrical Classes

4.2.1 Class G (General)

Class G helmets are intended to reduce thedanger of contact with low voltage conductors.Test samples shall be proof-tested at 2200 volts(phase to ground). This voltage is not intendedas an indication of the voltage at which thehelmet protects the wearer.

4.2.2 Class E (Electrical)

Class E helmets are intended to reduce the

danger of contact with higher voltageconductors. Test samples are proof-tested at20,000 volts (phase to ground). This voltage isnot intended as an indication of the voltage atwhich the helmet protects the wearer.

4.2.3 Class C (Conductive)

Class C helmets are not intended to provideprotection against contact with electricalhazards.




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7.2 Additional Requirements for Type IIHelmets

7.2.1 Impact Energy Attenuation

Type II helmets shall be tested in accordancewith Section 9.4 anywhere above the DTL.

Acceleration shall be recorded. Maximumacceleration shall not exceed 150 Gs.

7.2.2 Off-center Penetration

Type II helmets shall be tested in accordancewith Section 9.5 anywhere above the DTL.

For each condition specified, the penetratorshall not make contact with the test headformwhen struck anywhere above the DTL.

7.2.3 Chin Strap

Chin straps shall be made of suitable materialnot less than 12.7 mm (0.50 in.) in width.

Type II helmets which are provided with chinstraps shall be tested for retention inaccordance with Section 9.6.

For each condition specified, the chin strap shallremain intact. The residual elongation of thestrap shall not exceed 25 mm (1.0 in.).

7.3 Requirements for Optional Testing

7.3.1 Reverse Wearing

Type I Helmets that are to be marked with thereverse wearing marking shall pass the forcetransmission testing when mounted in thereverse position on the headform.

Type II Helmets that are to be marked with thereverse wearing mark shall pass the forcetransmission, impact attenuation, and off-centerpenetration testing when mounted in the reverse

wearing position on the test headform.

7.3.2 High-Visibility

When measured in accordance with Section 9.8of this standard, helmets marked “HV” for high-visibility shall demonstrate chromaticity that lieswithin one of the areas defined in Table 1 andthe total luminance factor (Y expressed as apercentage) shall exceed the correspondingminimum in Table 1.

Table 1. Color, High-Visibility Helmets

Color Chromaticitycoordinates

Minimumtotalluminancefactor

x y Y (%)

Fluorescentyellow-green

0.3870.3560.3980.460

0.6100.4940.4520.540

70

Fluorescentorange-red

0.6100.5350.5700.655

0.3900.3750.3400.344

40

Fluorescentred

0.6550.5700.595

0.690

0.3440.3400.315

0.310

25

8 Selection and Preparation of TestSamples

8.1 Headforms

8.1.1 General

Only that part of the headform above thereference plane is intended to represent the

human head. Damaged or deformed headformsshall not be used. Sources of headforms arelisted in Appendix E.

8.1.2 Headform sizes

The ISEA headform size 7 shall be used for theforce transmission test.

For all other tests, any of three sizes of ISOheadforms described in ISO Standard ISO/DIS6220 (See Figure 1) and specified by themanufacturer shall be used. If headform size is

not specified by the manufacturer, the testingfacility is to decide the most suitable size.

8.1.2.1 Headform for Force Transmission

The headform used for the force transmissiontest (Section 7.1.2) shall be the "ISEA standardheadform,” size 7 (approximate dimensions arecontained in Figure 3 for reference only). Theheadform 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 andmade from electrically conductive material shall

be used for the apex penetration test (Section7.1.3) 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 EnergyAttenuation Tests

An ISO headform used for the impact energyattenuation test (Section 7.2.1), shall be made ofa low resonance material such as cast silicaurethane, and have a Shore "D" durometer of 60

± 6. The headform, together with its supportingassemblies, shall have a mass of 5.0 kg ± 0.05

kg (11 lb ± 0.1 lb), with the center of gravityroughly corresponding to the center of themounting ball.

8.1.3 Reference Test Lines

The static test line (STL) is establishedaccording to the dimensions shown in Figure 11.The dynamic test line (DTL) is establishedaccording to the dimensions shown in Figure 2.

For the reverse wearing option, a separate DTLshall be established according to the dimensionsshown in Figure 2 for the helmets in which thetest sample is mounted on the headform in thereverse wearing position.

8.1.4 Headform Mountings

Headforms used in conducting the forcetransmission tests shall be mounted as shown inFigure 3. Headforms used for impact energyattenuation tests are mounted as shown inFigure 4. Headforms used for penetration testsare mounted as shown in Figure 5. Headformsused for chin strap retention tests are mountedas shown in Figure 6.

8.2 Test Samples

8.2.1 Compliance Testing

A minimum of 30 test samples is required forcompliance testing in accordance with theperformance requirements of Section 7.

A minimum of 36 test samples is required forcompliance testing for helmets that are to bemarked for wearing in the reverse position.

It is not intended that the testing protocolestablished in Table 3 be used for amanufacturer’s quality assurance program.

8.2.2 Sequence of Testing

Testing shall be conducted in accordance withthe schedule outlined in Table 3. Some test

samples may be used for performing more thanone test. Helmets meeting the requirements ofthis standard are intended to provide protectionagainst only one blow (impact and/orpenetration). If a test sample fails to meet therequirements of a given test (with the exceptionof Class E electrical insulation test) and thesample has previously been subjected to animpact or penetration test, a new helmet shall betested to verify the "failing" result of thatparticular test. Should the new helmet meet thetest requirements, then the "failing" result shallbe discounted.

8.2.3 Testing Conditions

All testing shall be performed at room

temperature 23°C ± 2°C (73.4°F ± 3.6°F). Ifthere is a disagreement in the test resultsamong different laboratories, the helmets shallbe 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 ofISO headform appropriate for the helmet beingtested, whose circumference is not greater thanthe internal circumference of the helmetheadband when adjusted to its largest setting,shall be used. If no headband is provided, thecorresponding interior surface circumference ofthe helmet shall be used to determine theappropriate headform. Once the appropriatereference headform is chosen, the test samplesshall be adjusted to provide a snug, but not tight,




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fit on the headform. All samples shall bemaintained at room temperature during marking.

8.3.1 Dynamic Test Line (DTL) MarkingProcedure

The headform shall be firmly seated with the

basic plane being horizontal. The test sampleshall be placed on the headform, centeredlaterally oriented in the normal wearing position,and seated firmly according to its positioningindex.

For samples that are marked to be worn in thereverse position, the headband shall be installedin the shell according to the manufacturer’swearing instructions for reverse donning. Thesample is then to be placed on the headform,centered laterally, rotated 180 degrees from thenormal wearing position along the basic plane ofthe headform, and seated firmly accordingly tothe manufacturer’s positioning index.

A 50 N (11 lb) static force shall be appliednormal to the helmet's apex. Maintaining theforce and position described above, draw a lineon the outer surface of the helmet coincidingwith the intersections of the helmet surface andthe following planes, as defined in Figure 2:

(1) A plane "k" mm above and parallel to thereference plane in the anterior portion of the

reference headform.

(2) A vertical transverse plane "b" mm behindthe center of the central vertical axis in a sideview.

(3) A plane "j" mm above and parallel to thereference plane in the posterior portion of thereference headform.

One test line marked sample for normal wearingand one marked sample for the reverse wearingoption should suffice for use in setting up the

subsequent testing.

8.3.2 Static Test Line (STL) MarkingProcedure

The headform shall be secured with the basicplane being horizontal. The test sample shall beplaced on the headform, centered laterally,leveled side-to-side and seated firmly accordingto its positioning index. A 50 N (11 lb) staticforce shall be applied normal to the helmet's

apex. Maintaining the force and positiondescribed above, draw a line on the outersurface of the helmet coinciding with thedimensions shown in Figure 11.

8.4 Helmet Preconditioning

8.4.1 Preconditioning Environments

Test samples shall be preconditioned prior toperforming the impact, penetration and chinstrap 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. Nosample shall be placed closer than 5 cm (2.0 in.)

to an internal oven wall. All specimens shall beplaced horizontal and in such a manner as tonot 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 temperaturepreconditioning may be used. Test samplesshall be placed in an environmental chambermaintained at –30°C ±2°C (-22°F ±3.6°F) for atleast four hours with the base of the helmetfacing 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-conditionedsamples shall be tested for impact andpenetration within 30 seconds after theirremoval from the conditioning environment.

Hot-, cold-, and lower temperature -conditionedsamples shall be tested for chin strap retention




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within 60 seconds after their removal from theconditioning environment.

Wet samples shall be withdrawn from the waterbath and positioned upright and horizontal for amaximum of 30 seconds to allow excess waterto drain. The wet samples shall then be

mounted on the applicable test apparatus andtested within 90 seconds from their removal ofthe 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 followingcomponents:

– 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 sufficientsize and strength to hold the test sample in anas-worn, upright position (see Figure 12). Thestand, including the attached test sample, shallbe placed inside a draft free fume hood.

9.1.3 Calibration

A temperature measurement device shall beused to verify the temperature of the Bunsenburner flame. With the Bunsen burner in avertical 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, measurethe temperature of the flame at the tip of theinner cone. It shall be 800 – 900°C (1472 –

1652°F). The use of natural methane(laboratory grade) gas with a heat content of

1000 BTUs ± 100 BTUs per cubic foot isrecommended.

9.1.4 Test Procedures

Attach the test sample to the laboratory teststand so that it is held in an as-worn, uprightposition (see Figure 12). Choose any point onthe outer surface of the helmet above the STLand apply the flame of the Bunsen burner suchthat the tip of the inner cone is within 2 mm (0.08in.) from the helmet surface. The Bunsenburner shall be held with its barrel horizontal. Apply the flame to the chosen test point for 5seconds +1 second, -0 second, then remove theflame. Inspect the test sample for any visibleflame 5 seconds after removal of the test flame.

9.1.5 Recording

Data recording is "pass" or "fail.”

9.2 Force Transmission


Test samples shall be conditioned according toSections 8.4.1.1 and 8.4.1.2.

9.2.2 Apparatus


– test headform;

– headform mounting fixture;

– electronic load cell and velocity indicator;

– impactor;

– vertical drop guide mechanism;

– electronic signal conditioning and recordingequipment.

A typical test setup is shown in Figure 7. Theheadform 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 ±

0.05 kg (8 lb. ± 0.1 lb). The striking face of theimpactor shall be spherical with a radius of 4.8

cm ± 0.8 cm (1.9 in. ± 0.3 in.) and a minimumchord length of 7.6 cm. (3.0 in.). The impactorshall be constructed in such a manner that it willremain rigid upon impact (single degree offreedom system). The load cell system shallconform 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 AppendixC.

The correctly mounted load cell assembly shallbe mounted between the headform and a steelplate at least 25 mm (1.0 in.) thick and at least0.3 m (1 ft) square. The plate shall be bolteddown to, and in intimate contact with, a concrete(or material of similar density) block thatmeasures approximately 1 x 1 x 0.3 m (3 x 3 x 1ft). The plate shall be leveled with a precision

level to ± 1° of horizontal. The center of theimpactor, the center of the headform, and thecenter of the load cell shall be co-linear asmeasured by a plumb bob. The alignmenttolerance shall be 3 mm (0.12 in.).

9.2.3 Mounting

Where the crown clearance is adjustable, thehelmet shall be mounted with the least amountof clearance.

The ISEA headform (as specified in Section 8.1)shall be used. The test sample shall bemounted with the STL horizontal and oriented inits normal wearing position. The impactor shallbe aligned along the central vertical axis of theheadform.

For the samples to be tested in the reversewearing position, the headband is to be installedin the shell according to the manufacturer’swearing instructions for reverse donning. Thesample is then to be placed on the headformwith the STL horizontal, and rotated 180degrees in the plane of the STL from the normalwearing position, and seated firmly accordinglyto the manufacturer’s positioning index.

9.2.4 Calibration

The instrumentation shall be stabilized andcalibrated. A suggested method(s) forcalibration is included in Appendix C2. Theequipment shall be checked for repeatabilitybefore and after each series of tests by

impacting a standardized elastomeric shock padas specified in the Appendix C3. A minimum ofthree such impacts shall be recorded before andafter testing. If the post-test average readings ofthe three impacts differ from the pre-testaverage by more than 5%, the entire test seriesshall be discarded.


Test samples per Table 3, Schedule of Testsshall be removed from the conditioning

environment (one at a time) and placed on thetest headform according to Section 9.2.3. Theelectronic recording device shall be zeroed aftera test sample is placed on the headform butbefore the impact. The impactor shall bedropped from a height that yields an impact

velocity of 5.50 m/s ± 0.05 m/s (18 ft/s ± 0.16ft/s).

9.2.6 Recording

The individual maximum force readings for alltest samples shall be recorded along with the

impact velocities. The values for hotconditioned test samples shall be averaged andthis result recorded. The values for coldconditioned, or optionally low temperature testsamples shall be averaged and recorded.

9.3 Apex Penetration


The test samples shall be conditioned accordingto Section 8.4.1.1 and Section 8.4.1.2.

9.3.2 Apparatus


– test headform;

– headform mounting fixture;

– electronic contact indicator and velocityindicator;




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– penetrator;


– 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 toany position that would allow the penetrator tostrike the helmet perpendicularly anywherewithin a 75 mm (3.0 in.) diameter circle aboutthe 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 penetratorconfiguration is shown in Figure 9.

The penetrator shall be constructed in such amanner that it will remain rigid upon impact(single degree of freedom system). Thepenetrator shall be guided and electricallyinsulated from the metal headform. The massand size of the base shall be as specified inSection 9.2.2. Wires shall be attached to theimpactor and headform such that if the impactormakes contact with the headform a low voltageelectric circuit is completed. A suitable meansof verifying said completed circuit can beobtained by use of an oscillographic recording.

9.3.3 Mounting

The largest size headform (as specified inSection 8.1) appropriate for helmet being testedshall be used. The helmet shall be mountedwith the STL parallel with the basic plane of theheadform and with the axis of the penetratoraligned with the center of the mounting ball ofthe headform.

9.3.4 Calibration

Before and after testing, contact of thepenetrator with the headform shall be made toassure that the electric circuit, when completed,is properly recorded by the recording device.


Test samples per Table 3, Schedule of Testsshall be removed from the conditioningenvironment (one at a time) and placed on thetest headform according to Section 9.3.3. The

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 dropshall be recorded. Data recording forpenetration is "pass" or "fail" based on anyindicated electrical contact.

9.4 Impact Energy Attenuation


Test samples shall be marked according toSection 8.3.1 and conditioned according toSection 8.4.

9.4.2 Apparatus


– test headform;


– uniaxial or triaxial accelerometer;

– hemispherical impact anvil;

– electronic signal conditioning and recordinginstrumentation;

– velocity indicator.

A typical test setup is shown in Figure 10 andthe headform/vertical drop guide mechanism isshown in Figure 4. Sources of equipment maybe found in Appendix E.

9.4.2.1 Mounting

The largest size test headform (as specified in

Section 8.1) appropriate to the helmet beingtested shall be used. The test shall be set up sothat the edge of the anvil does not extend belowthe DTL line of the helmet. The headform shallbe mounted as required for the anvil to strike thetest sample anywhere above the DTL. Thecenter of the accelerometer mounting hole,which will typically be the center of the headformmounting ball, shall be in vertical alignment withthe center of the anvil within 10 mm (0.38 in.).




Page 10

The impact shall be as normal to the surface asthe contour of the shell will permit.

If there are projections on the helmet’s outersurface above the DTL or internal projectionsinside the helmet above the DTL, the helmetshall be impacted directly on one of the

projections.

The test sample shall be mounted in its normalwearing position on the headform with the STLparallel to the basic plane of the headform.

For the samples to be tested in the reversewearing position, the headband is to be installedin the shell according to the manufacturer’swearing instructions for reverse donning. Thesample is then to be placed on the headformwith the STL parallel to the basic plane of theheadform, and rotated 180 degrees in the basicplane from its normal wearing position, andseated firmly accordingly to the manufacturer’spositioning 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 achord length of 7.6 cm (3.0 in.). The test anvilshall be rigidly mounted to a solid mass of atleast 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 contactwith a concrete block (or equivalent).

9.4.2.3 Test Headform

The headform along with its associated verticaldrop guide mechanism shall have a mass of

5.00 kg ± 0.05 kg (11 lb. ± 0.1 lb.) and beconstructed in such a manner that it will remainrigid upon impact (single degree of freedomsystem). The headform supporting assembly(vertical drop guide mechanism) shall not

exceed 25% of the mass of the total dropassembly. The center of gravity of the total dropassembly shall lie within a cone with its axisvertical, a 10° included angle, and with thevertex as the point of impact.

9.4.2.4

Accelerometer

The accelerometer is mounted at theapproximate center of gravity of the combinedtest headform and vertical drop guide

mechanism inside the headform mounting ball.The axis of the uniaxial accelerometer, or thevertical axes of a triaxial accelerometer, shall bealigned within 2.5 degrees of vertical. Theaccelerometer is connected to the signalconditioning/recording instrumentation. Theacceleration data channels shall comply with the

Society of Automotive Engineers (SAE)Recommended Practice J211 requirements forchannel class 1000. The accelerometer/recording system shall conform to the followingrequirements:

Accuracy = ± 2.5% Full Scale

Transverse Sensitivity = 3% max.

Resonant Frequency = 5 kHz min.

A system known to work is detailed in AppendixD.

9.4.3 Calibration

The instrumentation shall be stabilized andcalibrated. A suggested method(s) forcalibration is included in Appendix D2. Theequipment shall be checked for repeatabilitybefore and after each series of tests byimpacting a standardized elastomeric shock padas specified in the Appendix D3. A minimum ofthree such impacts shall be recorded before and

after testing. If the post-test average readings ofthe three impacts differ from the pre-testaverage by more than 5%, the entire test seriesshall be discarded.


Test samples per Table 3, Schedule of Testsshall be removed from the conditioningenvironment (one at a time) and mounted on thetest headform according to Section 9.4.2.1. Theelectronic recording device shall be zeroed aftera helmet is placed on the headform but before

the impact. The helmeted headform shall bedropped 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 berecorded along with its associated impactvelocity.




Page 12

shall slide freely in the vertical direction withinthe test stand.

The drop mass (impactor) shall also slide freelyupon 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 bechecked for freedom of movement before eachuse.


The test samples per Table 3, Schedule of Testsshall be mounted on the headform and the chinstrap threaded around the stirrup while the dropmass shall be held such that it does not interfere

with the pre-load assembly. The chin strap shallbe adjusted so that the stirrup rollers areapproximately in line with the pre-loadadjustment point specified in Figure 6. Thedeflection scale shall be zeroed with the 1.5 kg(3.3 lb) pre-load assembly in place. The dropmass shall be dropped onto the pre-load

assembly from 10.0 cm ± 0.5 cm (4.0 in. ± 0.2in.). A deflection reading shall be taken neitherless than 15 nor more than 30 seconds afterimpact.

9.6.5 Recording

The deflection (elongation) value shall berecorded for each test sample.

9.7 Electrical Insulation


Test samples tested for Class E requirementsshall first be subjected to the force transmissiontest, one conditioned hot and one conditionedcold.

9.7.2 Apparatus


– a vessel containing fresh tap water, of sufficient size to immerse the inverted helmet tothe water line;

– a frame for suspending the test sample in thewater;

– a source of 60-Hertz alternating currentvariable from 0 to 30,000 volts (root meansquare voltage) with at least a 20-milliamperecapability at 20,000 volts;

– wiring and terminals for application of voltageacross the crown of the test sample;

– a voltmeter of sufficient capacity to measurethe specified voltages;

– a suitable milliammeter of sufficient capacityand accuracy to measure the specified currents.

9.7.3 Calibration

Voltmeters and milliammeters shall be incalibration.


(See Section 8.3.2) Permanently attachedhelmet accessories (including welding helmetbrackets, lamp brackets, chin straps, etc.) shallbe retained on the test samples during testing.Non-removable chin straps shall be positionedsuch that they do not complete the electricalcircuit 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 upto the STL; unless the helmet contains holes inthe crown for mounting the suspension, in whichcase it shall be filled to 12.7 mm (0.5 in.) ofthose holes. No special provisions shall bemade for any accessory mounting holes abovethe plane of the suspension mounting holes.The test sample shall then be submerged in thesame type of water and to the same level as thewater on the inside of the helmet. The voltmeterand the milliammeter shall be attached to thecircuit. Care shall be taken to keep theunsubmerged portion of the test sample dry so

that flash over will not occur when voltage isapplied.

The voltage shall be applied, increased to 2200volts, and held for one minute. The currentleakage shall be recorded.




Page 13

9.7.4.2 Class E Testing

As with Class G testing, the inside of the testsample shall be filled with fresh tap water up tothe STL, or to a lower level but no lower than isrequired 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 thewater on the inside of the test sample. Thevoltmeter and milliammeter shall be attached tothe circuit.

Care shall be taken to keep the unsubmergedportion of the test sample dry so that flash overwill not occur when voltage is applied. Thevoltage shall be applied, increased to 20,000volts, and held for three minutes. The currentleakage shall be recorded.

The test sample shall then be tested for burn-through by further increasing the voltage to30,000 at the rate of 1000 volts per second andthen immediately reducing the voltage to zero.

9.7.5 Recording

For each test sample, the leakage currentand/or any evidence of burn-through shall berecorded.

9.8 High-Visibility Testing

9.8.1 Sampling and Conditioning

One test plaque shall be tested. The test plaqueshall 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, thetest shall be conducted within 5 minutes afterwithdrawal from the conditioning atmosphere.

9.8.1 Determination of Color

The color shall be measured in accordance withthe procedures defined in ASTM E1164–02

Colorimetry - Standard Practice for ObtainingSpectrophotometric Data for Object-ColorEvaluation with the following conditions:

1) set the spectrophotometer at a wavelengthrange of 400-700 nm and at intervals of 10 nmas stated in paragraph 7.3.1.2 of ASTM E1164;and

2) use illumination D65 and 45/0 or 0/45

geometry with 2° standard observer and a blackunderlay 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 ProtectiveHelmets

SAE J 211-1, 2007, Instrumentation for Impact

Test, Part 1, Electronic Instrumentation




Page 14

Table 2 –

Sizing Chart

CIRCUMFERENCEHAT SIZE

Centimeters Inches

6-1/2 52 20-1/2

6-5/8 53 20-7/8

6-3/4 54 21-1/46-7/8 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 asprohibiting larger or smaller headbands.




Page 15

Table 3 – Schedule of Tests

Test MethodMinimumNumber

OfSamples

TestSample

NumbersTest Sequence by Helmet Type & ClassIG IE IC IIG IIE IIC

9.1 Flammability 1 12 4 4 3 7 7 6

9.2 Force Transmission

HotCold or Lower Temperature

1212

1-1213-24

2 1 1 2 1 1

9.2 Force Transmission (reversewearing)


31-3334-36

33

2 1 1 2 1 1

9.3 Apex Penetration


33

25-2728-30

3 3 2 3 3 2

9.4 Impact Energy Attenuation

HotCold or Lower TemperatureWet

444

2-514-17

6,7,18,194 4 3

9.4 Impact Energy Attenuation(reverse wearing)


313234

111

2 1 1

9.5 Off Center Penetration


222

8,920,2110,22

5 5 4

9.4 Off Center Penetration(reverse wearing)


333536

111

2 1 1

9.6 Chin Strap Retention


111

111323

6 6 5

9.7 Electrical Insulation

a) 2.2 KV Type Ib) 20 KV Type Ia) 2.2 KV Type IIb) 20 KV Type II

2222

1, 131, 131, 241, 24

12

12




Page 16

Schedule of tests

Type I, Class G Helmets

Sample numbers 1 and 13 should be used for the electrical insulation test. Next, sample numbers 1–24should 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 13should then be used for the electrical insulation test. Sample numbers 25-30 should be subjected to theapex 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 exceptthe 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 1–24should be subjected to the force transmission test. Sample numbers 25-30 should be subjected to theapex penetration test. Next, sample numbers 2-7 and 14-19 should be subjected to the impact energyattenuation 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 performthe 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 and24 should be subjected to the force transmission test before conducting the electrical insulation testinstead 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 helmetsexcept 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 wearingposition. Samples numbers 31, 32, and 34 should then be subjected to the impact energy attenuationtest and samples numbers 33, 35, and 36 should be subjected to the off-center penetration testing in thereverse wearing mounting position.




Page 17

Figure 1 –ISO Headform




Page 18

Figure 2 – Dynamic Test Line (DTL)Impact and Penetration Tests




Page 19

Dimensions are approximate

Figure 3 – Force Transmission Headform




Page 20

Figure 4 – Typical Impact Energy Attenuation Headform Fixture

(all dimensions for reference only)

Figure 5 – Typical Penetration Headform Fixture




Page 22

Figure 7 – Typical Force Transmission Test Apparatus




Page 23

Figure 8 – Typical Penetration Test Apparatus




Page 24

Figure 9 – Typical Penetrator




Page 25

Figure 10 – Typical Impact Energy Attenuation Test Apparatus




Page 26

Figure 11 – Static Test Line (STL)

Electrical Insulation and Flammability Tests

Figure 12 – Flammability Test Apparatus




Page A1

AppendicesThe following appendices not part of American National Standard ANSI/ISEA Z89.1-2009, but areincluded for information only.

Appendix ARecommendations, 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.




Page A2

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.




Page A3

Appendix BElectrical 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 isrequired 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.




Page A4

Appendix CForce 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., mountedto 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 takeinto 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.


Resonant Frequency 20 kHz Min.

Frequency Response ± 0.5 dB @ 0.1 Hz - 2 kHz




Page A5

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 AThickness 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 accelerometerattached, 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 shouldbe 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.




Page A6

Appendix DImpact 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 beinterchangeable 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 headformsmay 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.


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.




Page A7

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.




Appendix ETest Equipment Sources

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

Impact/Penetration Monorail Test

Stands

SGS U.S. Testing Company, Inc.

291 Fairfield Avenue

Fairfield, NJ 07004-3885

(P) 973-575-5252

(F) 973-575-7157

www.ustesting.sgsna.com

ISO Headforms

Biokinetics and Associates Ltd.

2470 Don Reid DriveOttawa, Ontario K1H 1E1

CANADA

(P) 613-736-0384

(F) 613-736-0950

www.biokenetics.com

CADEX Inc.

175 Rue St. Paul

St. Jean-Sur Richelieu

Quebec, CANADA J3B 8N7

(P) 450-348-6774

www.cadex.com

ISEA Headform

Inspec Laboratories Ltd.

56 Leslie Hough Way

Salford, Greater Manchester M6 6AJ

UNITED KINGDOM

(P) 44 (0) 16 17 37 06 99

(P) 44 (0) 16 17 36 01 01

Load Cells




(P) 973-575-5252

(F) 973-575-7157


Kistler Instrument Corporation

75 John Glenn Drive

Amherst, NY 14120-5091

(P) 888-547-8537

(F) 716-691-5226

www.kistler.com

Accelerometers

PCB Piezotronics, Inc.

3425 Walden Avenue

Depew, NY 14043-2495

(P) 716-684-0001

(F) 716-684-0987www.pcb.com

Kistler Instrument Corporation

75 John Glenn Drive

Amherst, NY 14120-5091

(P) 888-547-8537

(F) 716-691-5226

www.kistler.com

Endevco Corporation

30700 Rancho Vieto Road

San Juan Capistrano, CA 92875

(P) 800-982-6732

www.endevco.com

Entran Devices, Inc.

10 Washington Avenue

Fairfield, NJ 07004

(P) 973-227-1002

(F) 973-227-6865

www.entran.com

Velocity Detectors

GHI Systems, Inc.

916 N. Western Avenue

San Pedro, CA 90732

(P) 800-GHI-SYST

(F) 310-548-5749

www.ghisys.com




(P) 973-575-5252

(F) 973-575-7157


Calibrating Medium

MTS Systems Corporation

14000 Technology Drive

Eden Prairie, MN 55344-2290

(P) 952-937-4000

(F) 952-937-4515www.mts.com




(P) 973-575-5252

(F) 973-575-7157


Data Acquisition/Computer

Systems

GHI Systems, Inc.

916 N. Western Avenue

San Pedro, CA 90732

(P) 800-GHI-SYST

(F) 310-548-5749

www.ghisys.com

ANSI-IsEA Z89.1 (2009) - American National Standard for Industrial Head Protection

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Transcript of ANSI-IsEA Z89.1 (2009) - American National Standard for Industrial Head Protection