Upholding Standard

How safe is your helmet? Here's exactly what is involved in bicycle helmets meeting Australian Standards.

Pacific Brands Leisure & Fitness handles the distribution of some major helmet brands within the Australian market including Bell, Rosebank and Giro. We spoke to Jim Brady, Product Manager for Rosebank, about helmet safety and Australia’s unique standards testing procedure.

Bicycling Australia Why does Australia have its own helmet standard? Why didn’t we just go with an existing international standard such as Snell?

Jim Brady Australia has always been considered a world leader in regard to safety—we were the first nation to introduce the mandatory wearing of seat belts for example (the law was introduced in Victoria in 1970). When looking to reduce bicycle related injuries it was decided to write a new standard that would offer reliably reproducible results.

The AS/NZS 2063 was based on the motorcycle standard and includes ‘batch testing’ which is one of the major differences between the Australian bicycle helmet standard and international standards such as Snell. With the Snell standard, the helmet is type tested to begin with and random tests are conducted once the product is on sale.

Adherence with Australian Standards involves the ongoing testing of sample helmets from every manufacturing batch to ensure continued conformity to the standard.

BA What is involved in getting a helmet passed by the Australian Standard?

JB Initially, a new helmet design must be third party certified in an independent lab. The testing is quite comprehensive and involves a number of steps.

They are checked to ensure that there are no internal or external projections that could cause injuries in an accident—this could include things like visors or anchor points for retention straps. The design is also checked to ensure that it doesn’t restrict your peripheral vision. All of the labelling and instructions for use and care are also checked.

Helmet stability is tested by placing a weight on the back of the helmet to check that it doesn’t fall back on your head. This is then reversed to ensure that it doesn’t fall forward and over your eyes.

Impact attenuation testing involves dropping the helmet from a height against a hard object and simulates a sizeable impact against the ground or a car.
Localized load distribution simulates an impact or a sharp or angled object such as a curb or the A-pillar of a car.

The retention system is also checked to ensure that the straps don’t stretch more than 25 mm.

Each of these tests is conducted on the one helmet sample. This is one of the most important differences between the AS/NZS 2063 test and Snell. The Snell test uses a new helmet for each step. To meet the Australian Standard, the helmet must pass the retention system test after it has already been subjected to the impact attenuation and localized load distribution tests. In a way it simulates an accident where there are multiple impacts and tests the helmet’s ability to stay in place.

After the helmet design gains approval, rigorous batch testing is conducted to ensure that compliance is maintained. Four helmets in every thousand are sacrificed for batch testing, but that could be four in 200 if the manufacturing batch only contains 200 helmets.

BA Where is the testing done—are there many places that are equipped to do the testing?

JB There are only a couple of independent labs that I am aware of—one in Sydney and another in New Zealand. We at Rosebank have our own certified lab so we are authorised to conduct our own batch testing here. Most don’t have that luxury and have to send samples from each batch to a testing lab.

BA Does the helmet manufacturer or importer have to pay to have the testing done?

JB Yes, it is all part of the cost that we have to bear.

BA Is it an expensive process?

JB It can be expensive but really depends on whether you have any issues in development. A helmet with a very conservative design may pass straight away while a really edgy lightweight design may require modifications before it is passed. In this case the tooling modifications at the factory can be horrendously expensive.

BA Does the expense make importing some small high end helmets unviable in Australia—especially when you have to destroy four out of every shipment that you bring in?

JB Yes, it can make it tough but the batch testing is probably less of an issue. There have been times where we have had to destroy several hundred helmets in the initial testing process, with design modifications along the way, before the helmet passed the Australian Standard.

BA Do global brands like Bell and Giro take Australian standards testing into account when designing helmets?

JB Yes, we give them feedback and some of the modifications that we have suggested have been included in their designs. In global terms the Australian market is relatively small. For them to make modifications purely for our market just isn’t viable sometimes.

BA A number of high end road helmets appear to have more vents than helmet. How can they possibly pass our tough Australian Standard?

JB They are often very cleverly designed using exotic materials and complicated manufacturing techniques.
Many use an internal skeleton made from plastic, carbon fibre or kevlar. It works like the bones in your body to give the structure integrity and stops the helmet breaking up on impact.

The exotic materials are extremely light and strong but also very expensive, which is in part why some helmets are so costly.

Elaborate shapes with vents on all sides also require more complicated tooling. A basic helmet may rely on a single tool for the mould while a high end model could require four or five different tools to form the required shape.

These tools fit together like a jigsaw and the internal skeleton has to be suspended in the mould as the foam is injected. It turns into a very complicated and labour intensive manufacturing process but the end result is a helmet that is safe, light, well ventilated and also looks extremely sexy.

High end helmets often use an internal skeleton to reinforce the structure. This allows for minimalist designs and excellent safety levels. Giro uses carbon reinforcement while Specialized’s new 2D relies on a kevlar internal frame.

BA Many mid to entry level helmets rely on a single shell size combined with some form of internal retention system to fill the gap between different head sizes. In some cases they may cover a 8 cm size variation. Is this a viable sizing method?

JB Yes it is. The retention system on that type of helmet will be securely attached to the EPS (expanded polystyrene) shell. Someone may have a small head but they are securely fastened in by both the straps and the retention system. The straps are the most important means of securing the helmet and the internal retention system is secondary. The internal retention system helps to provide a comfortable fit. A good range of shell sizes remains the best way to get a perfect fit but the AS/NZS 2063 standard does allow for widely adjustable retention systems.

BA In terms of safety, what aspects of helmet design should people consider when choosing a helmet?

JB Checking that the helmet is Australian standards approved is obviously the first thing. Beyond that, it is really important that the helmet fits correctly—both in terms of shell sizing and adjustment. It should offer a snug but comfortable fit, the straps need to be securely fastened and your forehead should not be exposed. Every helmet comes with fitting instructions and these must be followed.

Comfort is also an important factor. You need to select a helmet that you would be prepared to wear for the length of time that you intend to ride. There is no point buying a poorly ventilated helmet for extended road rides in a warm climate.

BA Do helmets have a ‘used by date’ and when should you replace your helmet?

JB Bicycle helmets are designed to absorb shock through partial destruction of the shell and liner. Any helmet that has been subjected to a severe impact should be destroyed and replaced immediately—even if no damage is visible. This rule applies regardless of the helmet’s age.

As a general rule, we recommend that helmets should be replaced every 3-5 years. The oil in your hair as well as hair sprays and gels can create changes in the EPS. Heat and ultra-violet light will also degrade the helmet’s polystyrene. As a result, the protective qualities of the foam liner will be compromised and the helmet may become brittle and more likely to break apart in the event of an accident.
It is best to play it safe and update your helmet periodically.

Images: John Hardwick

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