Energy-absorbing limitations of hard hat safety helmets in mitigating trauma from falling objects

The aim of the study was to analyze the effectiveness of hard hat helmets in mitigating head injuries from high-energy falling objects through a real-world case study, advanced numerical simulations and an uncertainty study. The study aims to answer the following research questions: (a) to what extent would the use of the protective helmet limit the kinetic energy of the falling construction prop, (b) whether the hard hat helmet would be damaged, and if so, to what extent, according to the helmet standards? A fatal construction accident involving a falling prop impact on the victim’s head was reconstructed using multi-body dynamics simulations and finite element analysis (FEA) based on uncertainty-based determination of initial conditions. The study quantified the impact energy, helmet damage and its energy-absorbing capabilities, and potential injury reduction compared to scenarios without a helmet. While the helmet absorbed significant energy (245% of the standard requirement) and reduced the Head Injury Criterion by 8–11%, the high impact energy ultimately proved fatal. This study highlights the limitations of hard hat helmets in extreme scenarios with high kinetic energy impacts. While helmets offer valuable protection, unrealistic expectations should not be placed on their ability to prevent all head injuries. The study not only enhances our understanding of the biomechanics of head injuries in such incidents but also provides practical implications for safety protocols and regulations.