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Advancement in materials for industrial safety helmets

V. Dhinakaran a,⇑, B. Gokhulabalan a, A. Rahul Kumar a, M. Ravichandran b
a
Centre for Applied Research, Chennai Institute of Technology, Chennai 600069, India
b
Department of Mechanical Engineering, K. Ramakrishnan College of Engineering, Tiruchirappalli, 621 112 Tamil Nadu, India

a r t i c l e i n f o a b s t r a c t

Article history: The energy absorbing capacity of the safety helmet mainly depends on the materials used for the fabri-
Received 14 September 2019 cation of the helmet. The researchers are working vigorously in the material with low weight and excel-
Received in revised form 19 November 2019 lent mechanical properties that a helmet should have. An attempt has been carried out to light the
Accepted 22 December 2019
various materials utilized for the manufacturing of safety helmet. Hybrid fibres are being developed with
Available online xxxx
different combinations to replace the existing materials for the fabrication of the helmet. In this study, a
review of the advanced materials developed as an alternative for conventional materials for the Industrial
Keywords:
Safety Helmet is done.
Safety Helmet
Composites
Ó 2019 Elsevier Ltd. All rights reserved.
Natural fibres Selection and peer-review under responsibility of the scientific committee of the First International
Advanced materials conference on Advanced Lightweight Materials and Structures.
Hybrid fibres

1. Introduction materials used for the fabrication of the helmets are substituted
by advanced materials. The advanced materials are biodegradable
The protection of employers is always a crucial concern in all and are easily decomposed [3,4]. The trending evolution in mate-
industrial related actions. The repeated accidents are due to falling rial heads towards the creation of the hybrid composites. These
of the object. It is observed from an International report that nearly are manufactured by blending natural and synthetic fibres
forty-eight thousand workers die every year because of the indus- together with matrix material. These advanced materials are
trial accidents. Hence, industrial safety helmets are employed to evolved to coincide the behavior of the synthetic as well as the nat-
secure the operators corresponding to the damages caused by the ural fibre [5,6]. The fibres are divided into two types. They are nat-
falling objects on the helmet and also act as the major source of ural fibre and man-made fibre. The full class is shown in Fig. 2 [7].
protection. The materials used for the helmets should have excel- The fibres obtained from nature is called Natural Fibre. These
lent shock-absorbing capacity and exceptional stiffness to provide fibres are highly suitable material that can be substituted for tradi-
protection. In addition to that, the material of helmet must grasp tional materials. These materials exhibit excellent behavior and are
the maximum energy from the impact and lessen the transmission cheaply available [8]. The fibres that are produced by the fusing
of the forces to the workers head. These factors essentially depend different materials are called man-made fibre. These man-made
on the characteristics of the material employed for the fabrication fibre are used in the engineering field such as automotive, aero-
of helmet. A number of researchers are working for enhancing the space etc. [9]. Gururaja et al. had presented his paper on the cur-
quality of the material used for the safety helmet to enhance the rent status of the hybrid materials [10]. In this research paper,
ability of the shock absorption by using advanced materials such the ideas proposed by various researchers for the selection of the
as polymers, natural fibres, and composites. A composite is formed materials for the production of the safety helmet is presented.
by combining two or different materials. The properties of the par- The future scope of the work is also discussed based on the review
ent materials are fused, and the composite shows enhanced behav- of the various papers.
ior than the base metal used. The composites are identified by
matrix and reinforcement material as it is shown in Fig. 1 [1,2]. 2. Materials used in industrial safety helmet
The rise in environmental problems leads to developments of
advanced materials such as natural fibre composites. The extant The work done by Saifee et al. on the behavioral study of the
coconut fibre in the several manufacturing disciplines yielded that
⇑ Corresponding author. fibre gives excellent tensile strength, high torsional toughness.
E-mail address: [email protected] (V. Dhinakaran). The authors had also intimated that it could be employed as an

https://doi.org/10.1016/j.matpr.2019.12.197
2214-7853/Ó 2019 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the First International conference on Advanced Lightweight Materials and Structures.

Please cite this article as: V. Dhinakaran, B. Gokhulabalan, A. Rahul Kumar et al., Advancement in materials for industrial safety helmets, Materials Today:
Proceedings, https://doi.org/10.1016/j.matpr.2019.12.197
2 V. Dhinakaran et al. / Materials Today: Proceedings xxx (xxxx) xxx

Fig. 1. Types of Composites.

Fig. 2. Types of Fibre.

alternative to the industrial safety helmet material [11]. The work (ABS) and polycarbonate (PC) are the subsisted materials which
carried by researchers for the development of the hybrid bio- are used in the making of Industrial helmet [16]. Table 1 shows
composites. Jute bio-fibres blend with glass fibres and in the form the result comparison of the various materials used for the fabrica-
of pultruded sheets to prepare the bio-composite. They had fabri- tion of the helmet. It is found that the composite such as coir fibre
cated the helmet by using these bio-composites. They concluded reinforced epoxy exhibits excellent impact strength than other
that these bio-composites could be developed as the material for materials and the Table 2 shows the companions of various mate-
the making of the helmet because these are economically advanta- rials used for helmets.
geous [12]. Murali et al. had performed his work in the manufac- The military helmet is erected using coir fibre-reinforced epoxy
ture of the hybrid composites for the helmet. They have composite, which is included as an alternative material distinct
fabricated the helmet by using the hybrid composites. The hybrid from the regular plastic used. The weight percentage of fibre for
composite selected are banana, sisal, and jute. These hybrid com- the different compositions are 20, 40, 50, 60, 70, 80 and 85. The
posites results in fifty percent mass reduction of the helmet and specimen holding 70 wt% of fibre has max flexural strength at
also displays outstanding durability [13]. 31.88 N/mm2, impact strength at 8.733 J/mm2 and hardness is
Aly et al. had examined the composite case material for the hel- 30.03 HRF [17]. The work proposed by Rajasekar et al. is the inves-
met. The trial of the helmet is done by the drop test. The compos- tigation of properties of materials used in natural fibre helmet and
ites materials are correlated with Acrylonitrile Butadiene Styrene polypropylene helmet. The Industrial helmets are normally made
(ABS). The drop test is done to determine its impact strength. In of ABS plastics, the replacement for this is jute/banana/sisal parti-
their work, they had arrived at the conclusion that the composites cle fibre reinforced epoxy composite material. Flexural strength,
such as glass fibre woven fabric furnish more reliable properties Impact strength and weight of jute/banana/sisal particle fibre rein-
than ABS. Thus, these composite materials are an alternative mate- forced epoxy composite material are analysed with the ABS plas-
rial that can be used instead of ABS plastic for the production of the tics which are fabricated with (sisal/banana/jute) particle fibres
helmet [14]. The paper published by Yuhazri et al. in the filed for reinforced epoxy composite that are used for industrial safety hel-
the fabrication of the coconut fibre. It is reinforced with epoxy met [18]. The author compared the impact strength, weight and
composite. This material is used for the production of the safety
helmet [15].
The author observed the impact strength of the material as Table 1
9.95 J/mm2. He had concluded that this material could be used as Result comparison.
an alternative in place of the conventional materials used for the Material Impact Strength Tensile Strength(N/
helmet. The flexural, tensile and impact strengths of the material (KJ/m2) mm2)
used in Industrial helmet are determined and compared in this Coir fibre reinforced epoxy 26.43 23.68
method the fabrication of the helmet are done with the coir fibre composite
reinforced epoxy composite. The weight percentages of the coir Acrylonitrile butadiene styrene 10–29 46
fibre are assumed as 10, 20, 30, 40 and 50 and also the fibre length (ABS)
Polycarbonate (PC) 20–30 60
is taken as 30 mm for the tests. Acrylonitrile butadiene styrene

Please cite this article as: V. Dhinakaran, B. Gokhulabalan, A. Rahul Kumar et al., Advancement in materials for industrial safety helmets, Materials Today:
Proceedings, https://doi.org/10.1016/j.matpr.2019.12.197
 V. Dhinakaran et al. / Materials Today: Proceedings xxx (xxxx) xxx 3

Table 2 hybrid composite has achieved more desirable properties than

Various materials used for helmets. the jute fibre reinforced epoxy composite material [22]. The author
Material Example Properties has fabricated 9 composites by arranging the layers of fibres in dif-
Plastic  Acrylonitrile butadiene styrene  Good Impact ferent orders such as B, S, BS, G/B/G, G/S/G, G/BS/G, G/B/G/B/G, G/S/
 Polycarbonate resistance. G/S/G and G/BS/G/BS/G. These fabrication processes are done by
 High density polyethylene  High tensile compression moulding of randomly oriented banana, sisal fibre
 Polyamide 4,6 strength. with woven E-glass fibre. On the addition of 2 or 3 layers of E-
 Good shock
absorbing
Glass fibre, the tensile strength is increased by a factor of 2.34
capacity. and 4.13. The maximum tensile strength for the G/BS/G/BS/G is
 Dimensional 104 MPa and the maximum flexural strength is 192 MPa. When
stability. the external layers are glass fibre the maximum impact strength
Composite Matrix composite  Polymer  Good impact
for G/S/G/S/G composite sample is 13.3 J [23]. When the system
matrix strength.
 Metal  Good compression is compared with the non-woven composites the woven structure
matrix strength. exhibits the most remarkable properties under Impact, tensile and
 Ceramics  Light weight. flexural loadings. The author ends that the mechanical properties
matrix  High strength to of woven jute fabric reinforced polylactic acid composites obtains
Reinforcement  Reinforced weight ratio.
more preferable material evolution in this comprehensive domain
material composite plastics  Readily available.
 Glass fibre  Good tensile [24]. The mechanical characteristics of the natural fibre are anal-
 Carbon strength. ysed by Ajith with the fibre of length five to six millimetre. The
fibre  Design flexibility. composites are amalgamated by [18:82] fibre resin wt. percentage.
 Kevlar
The authors also states that the jute epoxy composites exhibit
fibre
Fibre Natural fibre  Silk  Excellent Impact more versatile mechanical properties when compared with (jute-
 Jute Strength. polyester) reinforced composite [25].
 Hemp  Very light weight. Ramesh et al. erected the banana fibre-reinforced epoxy com-
 Flax  Design flexibility. posite by using the hand lay-up technique with the weight per-
Man-made fibre  Carbon  Cheaply available.
centage of banana fibre 40%, 50% and 60%. It is terminated that
fibre  Amazing shock
 Glass fibre absorbing maximum tensile strength is 112.58 MPa and the maximum flexu-
 Polymer capacity. ral strength is 76.53 MPa at 50 wt% of banana fibres. The maximum
fibre  High stiffness. impact strength is of 11.22 J at 60 wt% of banana fibre. The research
 Ryan  Highly durable.
also recommends that 50 wt% of banana reinforced fibres can be
used as an alternative material for the reinforcement of conven-
tional fibre reinforced polymer composite used for the making of
flexural strength of (sisal/banana/jute) fibre reinforced composite safety helmets [26]. To fabricate the helmet shell of a hybrid of
with ABS plastics and observes that the impact strength, weight oil palm male flower bunch stalk fibre and oil palm frond fibre
and tensile strength of sisal/banana/jute fibres as 53.06 J/m, doing hand layup technique. The similar Technique used in the
292gm and 0.12KN respectively and in case of Acrylonitrile Butadi- other methods of fabrication (hand layup technique) is used here
ene Styrene the values are obtained as 50 J/m, 370 g and 1.10KN to fabricate the bi-directional jute fibre reinforced epoxy compos-
respectively [19]. ites. The void content largely affects the inter-laminar strength and
The Safety Helmet which is made of kevlar, glass and carbon flexural strength of the composite also when the weight percent-
fibres are investigated with the effect of the composite shell stiff- age of fibre increases the flexural strength first decreases and then
ness and also the impact on the dynamic response on safety hel- increases. The fibre volume fraction increases the tensile strength,
met. These effects are formulated by using LS-DYNA 3D FEA hardness, impact strength of Bidirectional jute fibre reinforced
code. The outer layer of the helmet is made of carbon, glass or Kev- epoxy composite [27]. The compression moulding technique is
lar fibre’s with the continuous woven mat and the inner layers are used to fabricate the jute fibre augmented polypropylene compos-
made of continuous glass fibre. Therefore it is concluded that Kev- ite by varying the weight percentage of fibre as 30, 40, and 50.
lar fibre shows more favourable response for the safety helmets as Among the materials developed by the author, the best combina-
it has low shear strength and high stiffness [20]. Fabricated fibres tion that suits the mechanical feature of the helmet material is
(jute/glass) reinforced polyester composites have variation in their polypropylene composite with 40% weight of the fibre [28]. It is
weight fraction ratio as 40/60, 50/50 and 30/70. The Impact observed that the impact strength is 41.11 J/m, hardness is 80.66
strength, flexural strength and Tensile strength of the developed No and the toughness is about 2.59 J are the developed hybridized
composite were observed. The authors resolved that the material composite. Therefore it is seen that the hybrid oil palm male flower
has tensile strength of 84.59 MPa and impact strength of 7.12 J and oil palm frond composite has excellent potential to succeed
for 50 wt% jute and 50 wt% glass fibre reinforced polymer is found the existing ABS Plastic which is used in present for the making
more eminent as compared to other developed compositions. The of helmet. The behaviour of the hybrid composites can be
flexural strength is obtained for the material as 113.93 MPa for enhanced by varying the weight of the component used in the pro-
40 wt% of jute and 60 wt% of glass fibre reinforced polyester com- cess [29]. Arunprasath et al. prevaricated that the helmet’s outer
posite, which is more powerful than recently developed compos- shell by use of coconut leaf midrib, coconut shell powder and glass
ites [21]. fibre reinforced epoxy composite using hand lay-up technique. The
The hand layup technique is used to analyse the engineering analysis of the helmet is done by the use of LS DYNA and relating
properties of jute and E-glass fibre reinforced epoxy hybrid com- the test and examination result. The coconut shell powder, coconut
posites. Sanjay et al erects four composites of each having the com- leaf midrib and glass fibre reinforced epoxy composite presented
position of L(1) with ten layers of glass fibre, L(2), L(3) with six choicer properties and hence it can be used as an alternative mate-
layers of jute fibre J/J/G/G/G/J/J and L(4) has G/G/J/J/J/J/G/G arrange- rial for the fabrication of Industrial safety helmet [30].
ments. The maximum tensile strength for the composition of L (1) The modelling and the examination of coconut fibre used in the
is of 280.25 N/mm2, flexural strength of 359.14 N/mm2 and impact inner shell of the safety helmet is displayed by using Catia and
strength of 11.4 J. The jute and E-glass fibre reinforced epoxy Ansys. The tensile and flexural strengths of improved coconut fibre

Please cite this article as: V. Dhinakaran, B. Gokhulabalan, A. Rahul Kumar et al., Advancement in materials for industrial safety helmets, Materials Today:
Proceedings, https://doi.org/10.1016/j.matpr.2019.12.197
4 V. Dhinakaran et al. / Materials Today: Proceedings xxx (xxxx) xxx

possess larger stress absorption as compared with Expanded Poly- 3.2. Composites and natural fibre
styrene Styrofoam (EPS). The produced composite is eco-friendly
and can be used as an alternative for the generation of the safety Vishal et al. [38] had investigated the analysis of the safety hel-
helmet [31]. The male bunch stalk fibre of palm oil is treated with met by using composites. The mechanical characteristics of the
conc. of 5% sodium hydroxide (Na-OH) and polyester as a mould material must resist the forces during accidental circumstances.
material by utilizing hand lay-up technique. This method is used Thus, the use of composites has increased because of its behavior,
for fabricating of anti-crash helmet. The impact strength is of like good impact strength. Bernd et al. had evaluated the safety
24.22 J/m, hardness is 71 in number and toughness is about 3.28 behavior of the safety helmet of carbon fibre. The work by Kulkarni
Joules for the above mentioned natural fibre. The results prove that in the field of safety helmet by introducing a carbon fibre compos-
the processing of male bunch stalk fibre with Na-OH increases the ites [39]. It has been suggested that these fibres give more power-
engineering properties of the composite material with 20 wt% of ful ballistic stability with reduced weight than the traditionally
cluster stalk fibre of oil palm reinforced polyester composite have used materials. He concluded that the polymer matrix nanocom-
proper material for the generation of anti-crash helmet. The sug- posites, primarily these strengthened by carbon nanotubes, pro-
gestion of the author states that the development of hybrid com- vide higher ballistic assurance [40]. Thomas et al. had conducted
posite also have a greater potential in the fabrication of car the impact analysis of GFRP composite. The investigation is carried
bumpers, dashboard, military and industrial safety helmet etc. out using Ansys. They inferred that the reinforcement of composite
[32]. The engineering properties of the newly developed hybrid fibres shows significant mechanical characteristics than the con-
composites are more desirable when compared with the other ventionally used materials [41]. Wazerya had explained about
commercially used ones. The total wt. percentage of fibre is up to the E-glass fibre, including random orientation of the reinforced
42%. The author had prepared four different types of sample and polymer. The fibre portions varies from 15%, 30%, 45%, and 60%
analysed. They ended the work with a solution that the hybrid by weight percentage. The importance of glass fibre had a direct
fibres have more salutary behaviour. They had succeeded in mini- impact on mechanical behavior. They had concluded that this glass
mizing the weight by 20%. Hence the hybrid glass/jute fibre- fibre composite improves the mechanical property of the materials
reinforced composite can also be used as an alternative material such as its hardness, tensile strength, and flexural bending strength
as it is a vulgar weight structure and also an eco- friendly material [42]. Elanchezhian et al. [43] carried out his work on the investiga-
[33]. The natural fibre such as sisal fibre-reinforced polymer com- tion of fibre composites. He had compared the result with GFRP
posite material along with sisal, okra, and jute reinforced hybrid and CFRP. The Impact strength of GFRP composite is more than that
composites have more desirable mechanical properties than sisal of CFRP. He found that the angle of the orientation of fibres plays a
fibre-reinforced polymer composite. The contact energy of the major part in the mechanical performance of CFRP and GFRP.
heterogeneous composite material is 33.6 percentage more emi- Ram et al. had done his work to review the qualities of natural
nent than the sisal fibre. The highest flexural strength of the hybrid fibre to substitute the present materials used for industrial safety
material is predicted to be 4.7 times greater than the sisal fibre. helmet [44]. Khan had studied the mechanical based attributes of
Thus, the author concluded that hybrid materials could be utilized knotted jute fabric reinforced with Polylactic acid. The woven
as an alternative to the material used in the automobile industry structure exhibits excellent properties than non-woven reinforced
and the generation of the helmets [34]. Polylactic acid [45]. Bajpai et al. had concentrated on the evolution
Chand et al. contrived the glass/ coconut fibre reinforced polye- of the hybrid glass/jute reinforced epoxy composite. These fibres
ster composites. The mechanical features of the advanced compos- are used for industrial safety helmet. Five distinct composites were
ites are estimated using the American standard for testing prepared and it was observed that the single layer of glass with
materials (ASTM). They inferred that the tensile behaviour of the three layers of jute reinforce epoxy hybrid composite reached the
fibre is enhanced by increasing the content of the fibre. The force highest flexural strength of 100.78 MPa. The research outcomes
needed to crack the glass fibre reinforced polymer composite is reveal that 3-Glass 1-Jute fibre reinforced epoxy composite shows
slightly greater than coconut fibre reinforced polyester composite the best impact strength. These can be adopted to replace the pre-
[35]. sent safety helmet material [46]. Sanjay et al. [47] had investigated
the mechanical features of jute/E-glass fibre reinforced epoxy
hybrid. The authors achieved that jute/E-glass fibre reinforced
3. Various materials for safety helmets epoxy hybrid has performed greater than the jute fibre. The use
of natural fibre-based polymer composite is increasing due to sev-
3.1. Plastics eral environmental and health concerns associated with synthetic
plastics [48,49]. Arpitha et al. [50] had produced the jute/glass
The most common materials used for the production of the safety fibres reinforced polyester composite. They had studied the behav-
helmet are ABS, High Density Polyethylene (HDPE), Polycarbonate ior due to varying weight percent of jute/glass. It was inferred that
(PC), and polyamide. The safety helmets manufactured using ABS the tensile behavior of the fibre is high when both jute and glass
shows excellent impact resistance, high toughness and easy to man- fibre are in equal proportion. Kumar had made the carbon/PCB
ufacture by injection moulding. Maiyuran et al. [36] published work powder epoxy composite that can be used for the fabrication of
for the manufacturing of the safety helmet using Polyamide 4–6 and the helmet. The best combination found by the author is
compared the result with ABS. The modelling and the analysis is car- 52/48 wt% of carbon PCB powder [51]. Arthanarieswaram investi-
ried out in Solidworks. He concluded that polyamide has better gated the impact of glass fibre fused with natural fibres. The
strength than ABS. They suggested that that the resistance against hybridization of the glass fibre enhances the tensile properties
the load per unit area is higher for polyamide than ABS. Obele and also improves the impact strength [23]. Gopalakrishna et al.
et al. [16] had studied the comparison of the impact strength of [52] had prepared the natural fibre composites mainly for engi-
the various plastics used for the fabrication of the helmet. They have neering purposes. A comparison study between the natural fibre
used ABS and Polycarbonate (PC) for the study. and synthetic fibre is made by the author. Gopinath had examined
Polycarbonate is found to have excellent impact strength than the mechanical features of jute fibre. They have used jute with
other plastics. Anil Kumar. K [37] led the mold flow study of the epoxy reinforced and polyester-reinforced epoxy composites. The
industrial safety helmet using pro/E software. He concluded that former exhibited greater mechanical characteristics than the latter
the Nylon 4–6 exhibits better strength than ABS. [53].

Please cite this article as: V. Dhinakaran, B. Gokhulabalan, A. Rahul Kumar et al., Advancement in materials for industrial safety helmets, Materials Today:
Proceedings, https://doi.org/10.1016/j.matpr.2019.12.197
 V. Dhinakaran et al. / Materials Today: Proceedings xxx (xxxx) xxx 5

Polymer science field has an emerging area in the natural fibre material scientists, industrialists and researchers will head to
composites. These low-cost fibres have a high specific property and the continuous improvement of the advanced materials that
a low-density. When compared with the conventional fibre com- can be substituted in the place of the existing materials.
posites they are further favoured as they are biodegradable and
hence does not affect the environment. It was specified that the
use of palmyra fibre as a reinforcement substance along with the
Declaration of Competing Interest
other composite materials offers high strength, light weight, flame
resistant, good insulating properties, chemical and weathering
The authors declare that they have no known competing finan-
resistance. Mostly the natural fibres are used as plastic composite
cial interests or personal relationships that could have appeared
reinforced material. The natural materials are highly opted for
to influence the work reported in this paper.
their toughness and strength. The development of new technolo-
gies leads to the urge in finding the replacement for a better prop-
erty of material in the new world. However, the development of References
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Please cite this article as: V. Dhinakaran, B. Gokhulabalan, A. Rahul Kumar et al., Advancement in materials for industrial safety helmets, Materials Today:
Proceedings, https://doi.org/10.1016/j.matpr.2019.12.197