Specification for non-metal helmets for the police force

IS 9562: Scope & Key Specifications for Wooden Headforms

• Scope:
  IS 9562 specifies requirements for wooden headforms used in testing helmets, ensuring uniformity and accuracy in helmet safety tests.

• Key Definitions (Clause 2.0):
  Defines terms related to headform dimensions, accuracy, and testing procedures.

• Accuracy (Clause 1.3):

  • Overall error in load measurement and recording must be ≤ 10%.

• Sampling & Conformity (Clause 8.1):

  • Follow IS 9695-1980 for sampling methods of helmets.

• Dimensional Tolerances (Clause 9.3):

  • Dimensional tolerance updated from 10 mm to 25 mm for specified measurements.

Typical Specifications for Wooden Headforms (per IS 9562)

flowchart TD
    A[Wooden Headform] --> B[Dimension Control (±25 mm)]
    A --> C[Surface Finish]
    A --> D[Load Measurement Accuracy ≤10%]
    B --> E[Sampling per IS 9695-1980]

Summary: IS 9562 governs wooden headforms for helmet testing with strict dimensional and accuracy criteria, referencing IS 9695 for sampling.

IS 9562: Definitions & Key Specifications

• Clause 2.0: Definitions
  This clause standardizes terminology used throughout the code for clarity and uniformity.

• Clause 2.10.3: Cradle

  • Adjustable assembly with anti-concussion tape and draw-lace.
  • Provides ventilation clearance and proper helmet fit.
  • Absorbs impact energy to enhance safety.

• Appendix D (Clause 9.4): Wooden Headforms

  • Specifies dimensions and materials for wooden headforms used in helmet testing.
  • Ensures consistent impact testing conditions.

• Appendix E (Clause 9.5): Water Absorption Test

  • Defines procedures to measure helmet material water absorption.
  • Ensures helmet performance under wet conditions.

Summary Table: Key Definitions & Specifications

If needed, I can provide detailed dimensions or test procedures from these appendices.

IS 9562:1980 — Materials Key Points

1. Protective Padding (Clause 2.9)

• Material must absorb impact energy and provide thermal insulation.
• Common materials: foam rubber, polyethylene foam, or similar.

2. Water Absorption Test (Clause 9.5, Appendix E)

• Determines moisture uptake of padding.
• Procedure:
  • Soak sample in water for 24 hours.
  • Measure weight before (W₁) and after soaking (W₂).
• Water Absorption (%) = (\frac{W_2 - W_1}{W_1} \times 100)

3. Material Specifications

• Padding density: Typically 20-50 kg/m³ for effective cushioning.
• Thermal conductivity: Low, to ensure insulation.
• Durability: Resistant to aging, weathering.

Summary Table: Water Absorption Limits

flowchart TD
    A[Material Sample] --> B[Weigh (W₁)]
    B --> C[Soak in Water 24h]
    C --> D[Weigh (W₂)]
    D --> E[Calculate Water Absorption %]

For detailed design, refer to IS 9562 Appendix E for test setup and acceptance criteria.

IS 9562 - Helmet Sizes and Specifications

Key Sizes (Clause 4.1)

• Helmet inside headband circumference sizes (mm):
  530, 540, 550, 560, 570, 580, 590, 600, 610, 620
• Tolerance: ± 3 mm

Measurement Method

• Use either a fixed plug gauge or an expanding gauge made of metal to measure helmet size.

Constructional Requirements (Related Clauses)

• Headform: Wooden headform as per IS 7692-1975.
• Supporting block for gauge and headform:
  • Concrete or similar monolithic block
  • Minimum dimensions: Height = 1 m, Length = 1 m, Width = 0.6 m
  • Mass: ~1 tonne
  • Block should be bedded on dry sand on a solid floor.

Summary Table: Helmet Sizes

This ensures helmets fit properly for safety and comfort as per IS 9562 guidelines.

IS 9562: Constructional Requirements Summary

• Support Block (Clause 1.4):

  • Concrete or similar monolithic block
  • Minimum dimensions:
    • Height = 1 m
    • Length = 1 m
    • Width = 0.6 m
  • Mass = 1 tonne
  • Bedding: On dry sand on a solid floor to support gauge and headform.

• Helmet Sizes (Clause 4.1):

  • Inside headband circumference sizes:
    530, 540, 550, 560, 570, 580, 590, 600, 610, 620 mm
  • Size tolerance: ± 3 mm
  • Measurement tools: Fixed plug gauge or expanding metal gauge.

• Water Absorption Test (Clauses 9.4 & 9.5):

  • Refer to Appendix D and E for detailed test procedures and requirements.

Key Notes:

flowchart LR
    A[Support Block] --> B[Concrete Block 1m x 1m x 0.6m]
    B --> C[Bedded on Dry Sand]
    C --> D[Supports Gauge & Headform]

    E[Helmet Sizes] --> F[530 to 620 mm Circumference]
    F --> G[±3 mm Tolerance]
    G --> H[Measured by Metal Gauge]

    I[Water Absorption Test] --> J[Appendix D & E]

For detailed construction and testing procedures, consult Appendices D and E of IS 9562.

IS 9562: Retention System Key Points

Definition (Clauses 2.10 & 5.3)

• Retention System = Headband + Chin Strap + Cradle
• Purpose: Keeps helmet securely positioned on the head.

Material Specifications (Clause 3.3)

• Materials must be:
  • Sweat-resistant
  • Non-irritant, no skin disease risk
• Chin strap & cradle: Polyethylene or similar material

Strength Requirements (Clause 9.3 & Appendix C)

• Load Test:
  • Maximum load: 0.5 kN (50 kgf)
  • Pre-load: 0.25 kN (25 kgf)
• Extension Limit:
  • Total extension between 0.25 kN and 0.5 kN load ≤ 10 mm
• Retention system must not fail under these conditions.

Summary Table: Retention System Strength Test

flowchart LR
    A[Helmet] --> B[Retention System]
    B --> C[Headband]
    B --> D[Chin Strap]
    B --> E[Cradle]
    C & D & E --> F[Material: Sweat-resistant, Non-irritant]
    F --> G[Polyethylene or similar for Chin Strap & Cradle]
    B --> H[Strength Test: Max Load 0.5 kN]
    H --> I[Max Extension ≤ 10 mm]

This ensures helmet stability and wearer safety per IS 9562.

IS 9562 Key Specifications & Weights

• Concrete Block (Clause 1.4):

  • Dimensions: 1 m (H) × 1 m (L) × 0.6 m (W)
  • Mass: 1 tonne (1000 kg)
  • Bedding: On dry sand over a solid floor

• Striker (Clause 1.5):

  • Material: Wood
  • Weight: 45 ± 0.1 kg
  • Striking face: 180 mm × 180 mm
  • Movement: Slides vertically on guide wires aligned with gauge center of gravity

• Specimen for Water Absorption Test (Clause 2.1):

  • Size: 25 cm × 50 cm pieces
  • Procedure: Weigh dry, immerse 24 hrs at 27 ± 2°C, reweigh after drying surface
  • Result: Report average % gain in mass

• Accuracy (Clause 1.3):

  • Overall system error ≤ 10%

Weight-related Notes:

flowchart TD
    ConcreteBlock[Concrete Block: 1m x 1m x 0.6m, 1000kg]
    Striker[Wooden Striker: 180mm sq face, 45kg]
    Specimen[Specimen: 25x50 cm for water absorption]
    Accuracy[System Accuracy ≤ 10%]

    ConcreteBlock -->|Supports| Striker
    Striker -->|Impacts| Helmet
    Specimen -->|Tested for| WaterAbsorption

This summarizes the key weight-related specs from IS 9562 for helmet testing setups.

IS 9562 Sampling & Criteria for Conformity (Clause 8.1)

• Sampling method and conformity criteria refer to IS 9695:1980 - Methods for Sampling of Helmets.
• This standard defines:
  • Sampling plan: Number of helmets to be randomly selected from a batch.
  • Acceptance criteria: Maximum allowable defects or failures for batch acceptance.
• Typically, sampling follows single or double sampling plans based on batch size.
• For example, a common acceptance plan might be:

• Helmets must meet performance requirements (Clause 9) to conform.
• Mass limit: ≤ 950 g excluding visor; if exceeded, mark mass to nearest 30 g (Clause 7.1).

flowchart TD
    A[Batch of Helmets] --> B[Random Sampling per IS 9695]
    B --> C{Number of Defects ≤ Acceptance Number?}
    C -- Yes --> D[Batch Accepted]
    C -- No --> E[Batch Rejected]

Summary: Sampling and conformity criteria for helmets under IS 9562 strictly follow IS 9695:1980, ensuring quality control through statistically valid sampling and acceptance limits.

IS 9562 - Performance Requirements Summary

The key performance requirements for helmets per IS 9562 are detailed primarily in the Appendices related to testing methods:

1. Shock Absorption Test (Clause 9.1, Appendix A)

• Helmets must limit the transmitted impact force to protect the head.
• Test involves dropping the helmeted headform from a specified height onto a rigid surface.
• Acceptance Criterion: Peak acceleration should not exceed a specified limit (typically around 250 g).

2. Flammability Resistance (Clause 9.6, Appendix F)

• Helmet materials must resist ignition and burning.
• Test involves exposing the helmet surface to a flame for a set duration.
• Acceptance Criterion: No sustained burning or melting that could harm the wearer.

3. Other Tests (Clause 9.4, Appendix D)

• Additional mechanical and environmental tests ensure durability and performance under various conditions.

Typical Shock Absorption Formula:

[ a = \frac{F}{m} ]

• a: acceleration (g)
• F: impact force
• m: mass of the headform

Summary Table (Indicative)

flowchart TD
    A[Helmet Sample] --> B[Shock Absorption Test]
    B -->|Pass| C[Meets Safety Criteria]
    B -->|Fail| D[Reject Sample]
    A --> E[Flammability Test]
    E -->|Pass| C
    E -->|Fail| D

Note: Refer to the finalized IS sampling standard and appendices for detailed procedures.

IS 9562: Marking Requirements for Safety Helmets

Key Marking Specifications (Clause 10.1 & 10.1.1)

Each helmet must be clearly and indelibly marked with:

• Manufacturer's name or trade-mark
• Year of manufacture

Optionally, helmets may bear the ISI Certification Mark to indicate compliance with ISI quality and testing standards.

ISI Certification Mark Details

• Governed by the Indian Standards Institution (Certification Marks) Act.
• Indicates conformity to IS 9562 under strict inspection and quality control.
• Continuous monitoring by ISI ensures ongoing compliance.
• Licensing for ISI Mark use is controlled by ISI; manufacturers must apply for permission.

Summary Table for Marking

This ensures traceability and quality assurance for safety helmets under IS 9562.

flowchart LR
    A[Helmet] --> B[Mark Manufacturer's Name]
    A --> C[Mark Year of Manufacture]
    A --> D{Optional}
    D --> E[ISI Certification Mark]
    E --> F[Compliance & Quality Assurance]

IS 9562: Shock Absorption Test Method - Key Points

Test Conditions (Clause 9.1 & Appendix A)

Helmets are tested within 1 minute after exposure to one of the following:

• a) 65 ± 2°C for 4 hours (oven)
• b) -10 ± 2°C for 4 hours (refrigerator)
• c) Water flowing over the helmet surface for 4 hours at room temperature

Test Setup (Appendix A, Clause A-2.1)

• Use a wooden headform as per specifications.
• Place helmet on the headform.
• A striker is dropped from 1.8 m ± 5 mm height onto the helmet.
• Record the force transmitted during impact using high-speed photography or instrumentation.

Important Specifications

Summary Diagram

flowchart LR
    A[Helmet Sample] --> B[Conditioning]
    B -->|Heat 65°C 4h| C[Shock Absorption Test]
    B -->|Cold -10°C 4h| C
    B -->|Water Flow 4h| C
    C --> D[Place on Wooden Headform]
    D --> E[Striker Drop from 1.8 m]
    E --> F[Force Measurement & Recording]

This test ensures helmets maintain shock absorption under environmental stresses.

IS 9562: Penetration Resistance Test Key Points

1. Test Types (Clause 9.2 & Appendix B)

• Plate Test:
  • Striker dropped from 1.8 m ± 5 mm onto helmet on headform (Clause 2.1).
  • No part of helmet shell should fail, stretch, dent, or pierce to touch the wooden headform.
• Plumb-Bob Test:
  • Same striker drop height.
  • No failure/stretching; maximum dent/penetration depth ≤ 10 mm.

2. Procedure Summary (Appendix B)

• Helmet conditioned as per Clause 9.1 (shock absorption worst case).
• Striker falls freely from height onto helmet on headform.
• Measure dent depth (plumb-bob test) or inspect shell integrity (plate test).

3. Important Specifications

4. Visual Concept Diagram

graph LR
A[Striker] -->|Drop from 1.8 m| B[Helmet on Headform]
B --> C{Test Type}
C -->|Plate Test| D[No shell failure/dent/pierce]
C -->|Plumb-Bob Test| E[Max dent ≤ 10 mm]

This ensures helmet integrity against penetration after impact conditioning.

IS 9562: Strength of Retention System Test Summary

Key Specifications (Clause 9.3 & Appendix C)

• Maximum Load: 0.5 kN (50 kgf)
• Pre-load: 0.25 kN (25 kgf) applied for at least 30 seconds
• Loading Rate: Additional 0.25 kN applied at 1 kN/min
• Maximum Extension: ≤ 10 mm between pre-load and max load
• Load Duration at Max: 2 minutes before measuring elongation

Test Procedure (Appendix C)

1. Apply pre-load of 0.25 kN for 30 seconds.
2. Increase load by 0.25 kN at 1 kN/min until 0.5 kN is reached.
3. Maintain max load for 2 minutes.
4. Measure elongation as vertical displacement difference between:
   • Reference point on retention device
   • Top of helmet shell
5. Elongation must not exceed 10 mm.

Additional Impact Test (Clause 2.1)

• Drop a 2 kg steel striker (32 mm diameter, conical tip 36°, tip radius ≤ 0.5 mm) from 1 m height on helmet crown.
• Check for any piercing, denting, or failure.

Formula for Elongation Measurement

[ \Delta L = L_{\text{max load}} - L_{\text{preload}} ]

Where:

• (\Delta L \leq 10 \text{ mm})
• (L_{\text{max load}}) = distance at 0.5 kN load
• (L_{\text{preload}}) = distance at 0.25 kN preload

flowchart TD
    A[Start: Mount Helmet on Headform] --> B[Apply Preload 0.25 kN for 30s]
    B --> C[Increase Load to 0.5 kN at 1 kN/min]
    C --> D[Maintain 0.5 kN Load for 2 mins]
    D --> E[Measure Elongation (ΔL)]
    E --> F{Is ΔL ≤ 10 mm?}
    F -- Yes --> G[Retention System Passes]
    F -- No --> H[Retention

Water Absorption Test - IS 9562 (Clause 9.5, Appendix E)

• Specimen Preparation:
  Cut 3 pieces of size 25 cm x 50 cm from the helmet shell. Seal cut edges with wax or sealing compound.

• Test Procedure:

  1. Weigh each specimen initially (W1).
  2. Immerse specimens in water at 27 ± 2°C for 24 hours.
  3. Remove, wipe surface dry, and weigh again (W2).

• Calculation:
  Water absorption (%) per specimen:
  [ \text{Water Absorption} = \frac{W2 - W1}{W1} \times 100 ]

• Acceptance Criteria:
  Average water absorption of the 3 specimens shall not exceed 5% of their original mass.

Summary Table

flowchart TD
    A[Cut 3 specimens 25x50 cm] --> B[Seal edges with wax]
    B --> C[Weigh specimens (W1)]
    C --> D[Immerse in water at 27±2°C for 24 hrs]
    D --> E[Remove & wipe dry]
    E --> F[Weigh specimens again (W2)]
    F --> G[Calculate Water Absorption %]
    G --> H{Is absorption ≤ 5%?}
    H -- Yes --> I[Pass]
    H -- No --> J[Fail]

This test ensures helmet shells resist water ingress, maintaining safety and durability.

IS 9562 - Firing Test Method (Clause 9.7 & Appendix G)

Key Specifications:

• Objective: Ensure helmet shell resists pellet penetration and excessive bulging.
• Acceptance Criteria:
  • No pellet shall penetrate the inner surface of the helmet shell.
  • Maximum allowable bulging of inner surface: 5 mm.

Test Setup:

• Use a Barthel burner as per IS 4355:1967 (A-1) for flame source.
• Employ a wooden headform specified in IS 9562 for mounting the helmet.
• Fire pellets at the helmet surface under controlled conditions defined in Appendix G.

Summary Table:

Notes:

• The fire-resistant brattice cloth may be used to simulate real fire exposure.
• Test ensures helmet safety against flame and projectile impact.

flowchart LR
    A[Start Test] --> B[Mount helmet on wooden headform]
    B --> C[Expose to flame using Barthel burner]
    C --> D[Fire pellets at helmet shell]
    D --> E{Pellets penetrate inner surface?}
    E -- Yes --> F[Test Fail]
    E -- No --> G{Bulging > 5 mm?}
    G -- Yes --> F
    G -- No --> H[Test Pass]

This method ensures helmets meet fire resistance and impact safety per IS 9562.