RETENTION TESTS
90 Under AS 2512.5, the strength of retention system test is to be conducted by positioning the helmet on a test headform of the same size designation as the reference headform used for determining the test line, in a position that conforms to its helmet positioning index. The helmet is to be secured so that it does not shift position prior to test. The retention system is to be positioned so that it does not interfere with free fall, impact or penetration. Under clause 6.1 of the Standard, the strength of the retention system test is to be conducted prior to the impact energy attenuation and resistance to penetration tests. Once the helmet is positioned, the helmet is to be secured so that the points of attachment of the retention system to the helmet are subjected to the same force as the retaining strap.
91 Next, a preliminary load is applied to the retention system of the magnitude and duration specified in the Standard. The force is to be applied normally to the basic plane of the test headform and symmetrical with respect to the centres of the retention assembly. Under clause 6.4 of the Standard the preliminary loading is 225 ±5N applied for 30 seconds. Next an additional load is to be applied to the retention system of the magnitude and duration specified in the Standard. Under clause 6.4, the additional load is 1,110 ±25N applied for 120 seconds. Under clause 6.4, the retention system or its attachments must not separate and the elongation between pre-loading and test loading is not to exceed 25 mm.
92 The tests were conducted at Crashlab by feeding the chin strap of the helmet through a roller attachment and fastening the chin strap. A vertical static load was then applied to the roller attachment for the requisite 30 seconds. The purpose of that first load was to eliminate any slack in the chin strap and comfort padding in the helmet. A measurement of the position at the top of the helmet was then taken and a measurement was also taken of the position of the roller attachment.
93 The additional heavier load was then applied to the chin strap for the requisite 120 seconds. Once again a measurement of the position at the top of the helmet was taken and a measurement was again taken of the position of the roller attachment. The overall test result was the difference between the measurements taken after the application of the two loads.
94 In the first test conducted by Crashlab, TR99/135, the four helmets passed the strength of retention system test. Those helmets were model EXR size M. The test in TR99/146 also related to model EXR size M helmets. All four helmets passed the strength of retention system test. The test conducted in TR99/147 related to model EXR size L helmets. Once again all helmets passed the strength of retention system tests.
95 The second test conducted on 23 March 1999, TR99/148, related to model RXR size L helmets. The helmet conditioned to ambient temperature failed the test while the other three helmets passed.
96 In TR99/189, two tests were conducted in accordance with the Standard. Those tests related to model EXR size XS and model EXR size XXL. In addition, two further tests were purportedly conducted but apparently not strictly in accordance with clause 7 of the Standard. As I have indicated, clause 7 requires that at least four helmets of the same size must be submitted for test. One of the purported tests in TR99/189 was in respect of two model EXR helmets both size L. The other purported test was in respect of four model MXR helmets, being two size S, one size XL and one size XXL.
97 While those tests do not appear to comply strictly with the Standard, no point was made by MHG in relation to that aspect of the tests. I assume, therefore, that the variations in sizes and the failure to test four helmets is not of significance. Nevertheless, the failure to adhere strictly to the requirements of the Standards tends to cast doubt on the reliability of the results, particularly where they are not conclusive.
98 All the model EXR size XXL helmets in TR99/189 passed the strength of retention system tests. The two model EXR size L helmets also passed.
99 The model EXR size XXS helmet which had been conditioned to high temperature failed the test as did the three model MXR helmets conditioned to ambient, high and low temperatures. Three of the failures were recorded as resulting from slippage of the webbing through the D-rings. The fourth failure, the model MXR size S, conditioned to low temperature, was recorded as exhibiting elongation of the webbing of 29 mm, 4 mm in excess of the maximum specified in clause 6.4 of the Standard.
100 Tests have been conducted by MHG in respect of 280 helmets. None failed the strength of retention system test. Of 30 helmets tested by Crashlab, 25 passed the test and only 5 failed. There is no evidence to explain conclusively why only some of the helmets failed the test. I shall deal below with some evidence that the webbing was of a different width on various helmets.
101 MHG sought to explain the failures on the basis of incorrect selection of the size of the headform for the purposes of testing the helmets. MHG contended that the results of the tests were unreliable because the use of a size B headform:
· permits horizontal movement which permits rotation of the helmet during testing;
· permits bowing or buckling of the helmet such that the chin strap may be extended, even after the initial load.
102 It was said that the Crashlab testing apparatus precluded the application of continuous static force and permitted a shear force. It was said that shear force permits an unequal application of the force being applied. More force is applied to one side of the webbing than the other. The unequal application of force permits the D-rings to slip in a manner not possible when force is applied properly.
103 AS 2512.5 states the scope of that standard as being to set out a method for determining the static strength of the retention system of a protective helmet and its attachment points. The principle of the test is stated as follows:
"With the helmet positioned on a fixed headform a static tensile force is applied to the retention system. The elongation of the retention system is then measured."
A note indicates that the value obtained for elongation of the retention system is not intended to include any reading due to compressing of any impact-attenuating material such as the crushable liner of a helmet.
104 I accept that, as a matter of principle, the bowing of a helmet could result in elongation of the strap. It does not result in any distortion of the strap but, because the points at which the strap is anchored to the helmet would be drawn closer together as a result of the bowing, the strap would extend lower. There was no quantification of such an effect and I am not satisfied that any bowing would result in a significant extension of the strap.
105 I also accept that if a helmet does not fit firmly on the headform, the application of a load could cause rotation of the helmet. However, if a helmet rotated, it would not result in any distortion of the strap. If a helmet rotated and, for example, tipped forward, the length of the strap could be elongated in that the strap could extend lower. However, the rotation would occur, as I understand the mechanism involved, upon the application of the preliminary load.
106 While there is a possibility of a certain amount of motion upon the application of the additional test load, Mr Gibson considered that the movement would be no more than 3mm. Mr Gibson said that in the tests that he observed at Crashlab, there was no further movement. The relevant measurement is taken of the difference between the position of the strap after the application of the preliminary load and after the application of the additional load. Even if there were any rotation, I do not consider that it would affect the test result.
107 I have indicated above my conclusion concerning the selection of the size of headform. I am not persuaded that Crashlab has erred in the selection of size B headform. Further, I am not persuaded that the apparatus employed by Crashlab results in the impermissible application of a shear force rather than a static force, assuming that the two are alternatives.
108 Another explanation proffered on behalf of MHG for failure of the strength of retention system tests, is inadequate fastening of the chin strap. There is, however, no evidence that the chin straps were inadequately fastened.
109 Mr Gibson considered that the retention system failures were too frequent to describe as random. Three of the failures occurred with the model MXR helmet, being three of the four helmets of that model tested. Only one of the 22 EXR models tested failed the test and only one of four RXR models tested failed the test. Mr Gibson observed that all of the failures were due to slippage of the webbing through the D-rings and considered that further investigation was necessary in order to find the cause of the failures.
110 Mr Gibson also observed that there was some variation in the components used in the retention systems that failed. In a subsequent report, he noted that two types of webbing were used in the retention systems of the helmets. Following measurement, Mr Gibson ascertained that of the 25 helmets available for measurement, 12 helmets had narrower webbing, 20.1 mm wide and 13 had wider webbing of 20.9 mm wide. None of the helmets with the wide webbing failed the retention system test.
111 Mr S.E. Hadanich, the General Manager of MHG, considered that since Mr Gibson's measurements of the webbing were taken after the retention test, the measurements could not be used as a basis to conclude that different webbing had been used by MHG in its helmets. However, no evidence was adduced on behalf of MHG as to that question. It would have been open to MHG to adduce evidence to demonstrate that only one thickness of webbing had been used. There was no evidence to suggest that the application of the test would distort the webbing to such an extent that the differences in measurement could be observed.
112 None of the evidence suggested that there was likely to be a difference in the performance of the retention systems of different models. The EXR and MXR models have identical shells. The rivet that attaches the retention system, however, is not in the same position. Accordingly, even if I were satisfied, on the balance of probabilities, that the retention system of the MXR model does not comply with the Standard, it does not follow that the retention system of the EXR model does not comply. That is to say, it may be that the position of the rivets securing the straps to the helmet has a part to play in the mechanism of the slippage that resulted in failure of the strength of retention system test.
113 I do not consider that the tests conducted by Crashlab demonstrate systematic failure of the retention system. Certainly Mr Gibson was of the view that the failures were not random. However, the number of helmets tested does not appear to be significant. There was no evidence as to the statistical significance of the numbers involved.
114 Further, while Mr Gibson considered that the failures were not random, no explanation was offered as to the mechanism of failure based on width of the webbing. As I have indicated, MHG did not accept that there were two sizes of webbing. In the circumstances, I am not satisfied from the evidence presently before me that, on the balance of probabilities, the retention system does not comply with the Standard.