In collaboration with and funded by the John R Gentille Foundation, ELECTRI International, the American Society of Concrete Contractors, and The Association of Union Constructors, we have evaluated construction helmets using the STAR testing system. This system assesses each helmet’s ability to reduce linear and rotational head acceleration during a range of oblique fall scenarios representative of severe but survivable construction site accidents. Helmets earning more stars are associated with lower concussion and skull fracture risk in these scenarios. We recommend 4- and 5-star rated helmets for workers exposed to fall hazards.

These data highlight the superior impact protection of Type 2 helmets compared to traditional Type 1 hard hats. For more information on why upgrading to Type 2 helmets matters, see Hard Hats to Helmets.

New and not previously tested helmets will be added to the ratings on a continual basis.

• infoUnderstanding the rating system
  Our ratings are an independent and objective assessment of helmet performance for consumers, free from manufacturer influence.
  
  Each construction helmet is evaluated through a series of oblique drop tests representing severe but survivable falls, identified from job-site accident reports. A medium NOCSAE headform is dropped onto a 25° steel anvil coated with 80-grit sandpaper at two speeds: moderate (5.5 m/s) and high (6.8 m/s). Linear and rotational head accelerations are measured for every impact and correlated to brain and skull injury risk.
  
  
  A total of 12 laboratory impacts are performed per helmet, with a new sample used for each test. Three impact locations, selected from real-world fall data and distributed around the helmet, are tested at both speeds, with two trials each. Each impact condition is weighted according to how frequently that type of fall is expected to occur on construction sites. Concussion risk and skull fracture risk are computed from the measured accelerations, multiplied by their weighting factors, and summed to produce an overall STAR score.
  
  The weightings represent a distribution of 100 fall-related head impacts. The STAR score therefore predicts the number of head injuries a worker would sustain if exposed to 100 such impacts. Because we evaluate both concussion and skull fracture risk, the maximum STAR score is 200 (reflecting the possibility of sustaining both injuries from a single fall).
  
  A lower score indicates better helmet performance.
  
  Note that STAR scores in these ratings are not directly comparable to those in our ratings for other sports or activities, because test methods, impact conditions, risk models, and weightings differ.
• file_downloadTechnical documents
  Test Protocol: Gagliardi SM, Stark NE‑P, Edwards LM, Begonia MT, & Rowson S. STAR Protocol for Construction Helmets (2025).
• sticky_note_2Notes about these ratings
  A lower score offers better protection.
  
  Type vs Class: Type I helmets are designed primarily for top impacts; Type II are designed for top and lateral impacts. Electrical class ratings (C/E/G) indicate different levels of electrical protection and are independent of impact performance.
  
  *Any worker can sustain a head injury even with the very best head protection. This analysis is based on data trends and probabilities; an individual’s risk may vary with health history and impact factors.