DEVELOPMENT OF SMART PROTECTIVE HEADGEAR SYSTEM

MID TERM REPORT

DEPARTMENT OF CIVIL ENGINEERING

NED UNIVERSITY OF ENGINEERING AND TECHNOLOGY KARACHI, PAKISTAN

DEVELOPMENT OF SMART PROTECTIVE HEADGEAR SYSTEM

BATCH: 2017

By

NAME SEAT NO

1. MUHAMMAD ARSALAN ASHRAF CE-170712. SYED DANISH JAVED CE-17072

3. MUHAMMAD SHARIQ SIDDIQUI CE-17074

4. BILAL AHMED CE-17075

5. MUHAMMAD ALI BUKHARI CE-17077

6. MUHAMMAD OMER ALI SIDDIQUI CE-17105

7. MUHAMMAD JUNAID KHAN CE-17307

DEPARTMENT OF CIVIL ENGINEERING

NED UNIVERSITY OF ENGINEERING AND TECHNOLOGY KARACHI, PAKISTAN

ii

TABLE OF CONTENTS

Page No.

TITLE PAGE i

TABLE OF CONTENTS iii

LIST OF TABLES iv

LIST OF FIGURES v

LIST OF ABBREVIATIONS/SYMBOLS vi

CHAPTER 1: INTRODUCTION 1

1.1 Background 1

1.2 Problem Statement 1

1.2 Objectives 2

1.2 Scope 2

1.2 Expected Outcomes 2

1.2 Beneficiaries 2

CHAPTER 2: LITERATURE REVIEW 3

2.1 General 3

2.2 Literature Collection 3

2.3 Smart Safety Helmets

2.4 Benefits of Smart Safety Helmet

2.5 Different Types of Helmets

2.5.1 The Smart Hard Hat

2.5.2 Pro-Active Helmet

2.5.3 Cooling Hard Hat

2.6. Safety Standards

2.6.1 EN 397 2012 (Industrial Helmet)

2.6.2 OSHA (Occupational Safety And Health Administration)

2.6.3 ANSI (American National Standard Institute)

2.7 Occupational Injuries In Pakistan

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2.7.1 The Factors Contributing to Construction Accidents In Pakistan

2.7.2 Reasons for Safety Non-Compliance

2.8 Summary

CHAPTER 3: METHODOLOGY 7

3.1 Introduction

3.1.1 Literature Review

3.1.2 Questionnaire Design

3.1.3 Data Analysis

3.2 Study Aim

3.3 Questionnaires Design

3.3.1 First Questionnaire

3.3.2 Second Questionnaire

3.4 Data Analysis and Collection

3.4.1 Market Survey

3.4.2 Labour Survey

CHAPTER 4: PROGRESS OF WORK 11

4.1 Overall Project Schedule/ Timeline 11

4.2 Progress To Date 11

4.3 Remaining Work and Challenges 11

REFERENCES 12

iv

LIST OF TABLES

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Table 3.1: Helmets and Their Specifications Used in the Local Market 10

Table 4.1: Dust Sensor Cost 16

Table 4.2: Sound Detector Cost 16

Table 5.1: Relation Between ADC Value and Intensity of Sound 27

Table 6.1: Results of Simulation 34

LIST OF FIGURES

Figure 2.1: Methodology 2

Figure 3.1: Survey: Age of Labours 11

Figure 3.2: Survey: Limitation of Head & Neck 11

Figure 3.3: Survey: Near Miss 12

Figure 3.4: Survey: The Most Affected Part of The Body 12

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LIST OF ABBREVIATIONS

3D 3-Dimensional

ABS Acrylonitrile Butadiene Styrene

IDE Integrated Development EnvironmentLED Light Emitting DiodeMPa Mega PascalOSHA Occupational Safety and Health AdministrationuF Micro FaradsV Volt

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CHAPTER NO. 1

INTRODUCTION

1.1 BACKGROUND

The risk of head injury to labourers is continually present. The most genuine risk is physical

wounds, which can be because of a falling item or crash with fixed articles in the work

environment. Because of the idea of these work exercises, it isn't generally conceivable to

wipe out such dangers with simply suitable hierarchical arrangements or aggregate defensive

gear. Subsequently, the best way to guarantee labourers security is by utilizing a well-being

protective headgear system.

It has been considering over the years that the usage of safety helmet has become essential.

Still, lack in it like usage of heavy materials has reduced the labour productivity of the

labourers and has increased the incidence of accidents at the construction sites. Therefore,

smart safety helmets are designed to look after the comfort of workers.

To successfully diminish head injury dangers, a suitable kind of safety helmet ought to be

given. The safety helmet chooses to fulfil certain presentation necessities, including shock

absorption, resistance to penetration, and customizable to fit and agreeable to the user.

Wearing a hard hat can prevent or at least reduce the risk of a head injury.

1.2. PROBLEM STATEMENT

Construction workers are at a high stake of getting an injury during work, especially on their

heads. The reason for head injuries could be striking against a fixed, moving, or falling

objects, or getting slipped or tripped overhead (Shafique & Rafiq, 2019). To avoid such head

injuries, workers must wear a safety helmet all the time whose job is to protect the head from

getting injured. Wearing the helmet for the whole time makes it unbearably warm (Hsu Tai &

Chen, 2000), and it starts being felt heavier and irritating. The existing helmets do not provide

much strength, and several head-related injuries in the construction industry are reported every

year. 481 injuries along with 16 casualties are reported in Hong Kong from 2011 through 2017

(Shafique & Rafiq, 2019)

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1.3. OBJECTIVES

Following are the objectives of the project:

1. To design the Smart Protective Headgear System to minimize the chance for hazards

to cause head injuries.

2. To develop a simulation of a Smart Protective Headgear System through FEM,

which consists of different elements such as Dust Detector, Sound detector, and

Cooling Strap.

1.4 SCOPE

The scope of the project is to develop a Smart Protective Headgear System for the safety of

labourers with the aid of simulation on the helmet yet showing the assessments regarding ABS

plastic helmets and Kevlar for the strength where it fails. It further includes the thermal check

and the results detecting excessive sound and dust particles.

1.5 EXPECTED OUTCOMES

Following are the expected outcomes of the project:

Development of design of a safety helmet that would remain cool by using a cooling strap

during long working shifts to provide comfort to the labour and create ease in doing his

job.

The design would incorporate greater strength via Kevlar, which would give more safety

to the labourer and hence reducing the risk, casualties, and injuries related to the head

especially.

1.5 BENEFICIARIES

The key beneficiaries of the project include:

1. The labourers who would get a more comfortable, strong and light weight safety

helmet that can go a long way in reducing head-related injuries and fatalities

2. The supervisors and site management, who would be able to improve site safety

performance

3. The project managers as well as the contractors, whose safety indicators on

construction projects would improve.

4. The construction industry, which can prove to be more safe for its labourers and

stakeholders

5. The safety gadgets manufacturers, who can use this design to develop a new breed of

safe, light weight and comfortable commercial safety helmets for the local and

international construction industries.

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CHAPTER NO. 2

LITERATURE REVIEW

2.1 INTRODUCTION

This chapter comprises of a discussion about the relevant literature collected from different

sources for employee safety.

2.2 LITERATURE COLLECTION

The literature collected for the project mainly focuses on the need to develop the Smart

Protective Headgear System that will fulfil the requirements of safety needs and provide the

safety of labourers for an ultimate decrease in site accidents.

2.2.1 SOURCES

The collection of literature was done from the following sources:

Research journals and publications

Training tutorial

Guidelines from safety standards

2.3 SMART SAFETY HELMETS

Among the aspects of any organization, the most important is employee safety. According to a

2012 white paper by the Occupational Safety and Health Administration, more than 4.1

million workers suffer a serious job-related injury every year. According to the report, in

almost half of the accidents involving head injuries, and enhanced focus is on preventing these

numbers down. To accomplish this, a protective headgear system with leading-end –

technology is creating a safer helmet to increase productivity, efficiency, and effectiveness of

work.

2.4 BENEFITS OF SMART SAFETY HELMET

A smart safety helmet protects one's head from falling objects such as stones, concrete, pillars,

and bricks. The device combines with various sensors to deliver immediate feedback to both

workers and their supervisor for any accident that occurs, but wearing a smart safety helmet

can also increase work efficiency by reducing the work danger on the job site. Smart Industrial

helmets provide safety and connectivity benefits.

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2.5 DIFFERENT TYPES OF HELMETS

2.5.1 THE SMART HARD HAT

Our smart helmet is used by indoor and outdoor labours to monitor their positions or locations

as they work. The device combines a variety of sensors and components, along with a central

processing board. In a market commanded by brands, for example, 3M, Honeywell, and MSA,

the Smart Hard Hat gives a new way to deal with the Environmental Health and Safety (EHS)

observing accessible to the most basic workers. Keeping costs sensible will guarantee that this

gadget is accessible to all degrees of physical labourers (2016, cited November 19, 2019)

2.5.2 PRO-ACTIVE HELMET

The head protector is fixed within a delicate and adaptable material under ordinary conditions,

yet which "locks" momentarily, getting hard and stun spongy if the cap is exposed to impact or

blows. Radio or radio connections or gas detectors would all be able to be mounted on the

protective cap as per the individual client (SINTEF. 2019 cited October 13, 2019).

2.5.3 COOLING HARD HAT

A fan with a motor is attached at the top of the helmet inside to blow air. The motor takes

energy from a rechargeable battery. The rechargeable battery may be charged by a battery

charger associated with the solar cell and can be alternatively associated with an electrical

outlet by a charging string. A switch allows the user to control whether the motor is powered

or not. ((fibre) C, stroke H)

2.6. SAFETY STANDARDS

2.6.1 EN 397 2012 (INDUSTRIAL HELMET)

Falling object to protect

Protect from lateral deformation

Shock absorption

Vertical penetration resistance

Flame resistance

Electrical insulation (Satra.com. 2019 [cited 19 November 2019])

2.6.2 OSHA (OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION)

OSHA has two standards that govern hard hat requirements:

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29 United States Code of Federal Regulations (CFR) 1910.135 governs hard hat

requirements for general industry workers

29 CFR 1926.100 refers to head protection requirements for construction, demolition, and

renovation workers.

2.6.3 ANSI (AMERICAN NATIONAL STANDARD INSTITUTE)

ANSI Z89.1 proposes that the safety helmet must have a peripheral shell and a permeable

covering that consolidates the web and lashes that expand or suspend the shell from 1 to 1/4

inches (2.54 cm to 3.18 cm) away from the head. Such a setup gives stun assimilation during

an impact and ventilation during commonplace wear.

Hard caps are separated into three modern classes:

Class A hard caps furnish effect and infiltration opposition alongside restricted voltage

assurance (up to 2,200 volts).

Class B hard caps give the most significant level of assurance against electrical perils,

with high-voltage stun and consume security (up to 20,000 volts). They additionally give

insurance from effect and infiltration perils by flying/falling items.

Class C hard caps give lightweight solace and effect assurance yet offer no insurance from

electrical dangers.

Another class of guarded headgear accessible is a "bump hat," planned for use in districts with

low head opportunity. They are endorsed for regions where assurance is required from head

knocks and gash. These are not proposed to make sure about against falling or flying things

and are not ANSI endorsed.

2.7 OCCUPATIONAL INJURIES IN PAKISTAN

Globally, Pakistan was ranked nine the populated country in 2010, with a total labour force of

54.9 million. (Zahoor, 2020)

Every year, in occupational injury/ incidences, 41 workers out of 1000 receive injury in

Pakistan, most unskilled labourers are unaware of using protective equipment, precautionary,

and safety measures.

2.7.1 THE FACTORS CONTRIBUTING TO CONSTRUCTION ACCIDENTS IN

PAKISTAN

In Pakistan, 7.3 percent of the all-out work power is utilized by the construction business;

nonetheless, its mishap rate is 14.1 percent, which is higher than that in different industries 5

(PBS, 2014). No huge decrease has been seen during the most recent seven years, as the injury

rate remained practically reliable at more than 14 percent (PBS, 2007, 2014). (PBS, 2007,

2014). Most construction accidents are caused by a fall from a height, followed by those

caused by lifting activity. (Zahoor, 2020)

2.7.2 REASONS FOR SAFETY NON-COMPLIANCE

Non-compliance to security guidelines is credited to; non-presence of any administrative

power, eagerness for making more benefit, thinking that investing in the safety of workers will

increase the overall cost of the project, not thinking and ignoring the rights of labours, no

safety measures, and their respective techniques, political involvement, helping in corruption,

meeting those deadlines which are impossible, more working hours, less or none safety

training, no certification for the labours about safety, hence giving none value to human

beings.

2.8 SUMMARY

It is apparent from the above talk that there are advantages of normalized benefits of the

executive frameworks, remembering a decrease for mishaps and dangers. What's more, there

is a move towards coordinating various kinds of executive frameworks into a solitary

framework that manages safety, business targets, and hierarchical objectives. There is some

proof to propose that the advantages of these frameworks as a mishap diminishing instrument

can be momentary just except if the board is focused on the framework and know it's a benefit

for their business. It includes education and proper training of workers. This concluded that in

order to increase the efficiency of work and to provide safety to labourers smart helmet is

necessary where it provides effective contact with the labour and their supervisor to predict the

accidents, which can result in reducing head injuries in the future.

CHAPTER NO. 3

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METHODOLOGY

3.1 OVERVIEW

This chapter contains the methodology adopted to carry out the work for this project. In line

with the key objective of this study i.e. to find out the suitable parameters in developing the

Smart Protective Headgear System, this study consists of the phases as described in the

following sub-sections and depicted in the diagram of Figure 3.1.

Figure 3.1: Project Phase-Wise Methodology

3.1.1 LITERATURE REVIEW

The existing research and reports had been reviewed to understand how much development in

solving this problem has been made.

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DEVELOPMENT OF SMART PROTECTIVE HEAD GEAR SYSTEM

Phase 2 Phase 3 Phase 4Phase 1

Proposal

Literature Review

Questionnaire Formation

Wish List

Result and Graph of Stress

Analysis

Stress Analysis Using Inventor

Survey

Approval of Project

Report Writing

Sound Detector

Thermal Simulation

Dust Sensor

3D Design/ Modeling

Result and Conclusion

s

Tracking Simulation

3.1.2 QUESTIONNAIRE DESIGN

Two questionnaires were designed to make the study and analysis more factual and to validate

the established problem further.

3.1.3 DATA ANALYSIS

The data obtained through the questionnaires and the recommendations made by the workers

were taken critically into consideration before moving towards the next step, i.e., the

designing of the Smart Protective Headgear System.

3.2 STUDY AIM

Head injury is one sort of major word related mishaps in Pakistan, especially in the

construction site. Consistently numerous labours are harmed or are even killed because of

head injury. The primary dangers of head injury in the work environments are as per the

following.

Where there is a possibility of a labourer being struck down by a falling object on his

head.

Where a labourer can strike his head against the construction machines during the section.

To successfully diminish the dangers of head injury, a suitable kind of safety helmet ought to

be given. The safety helmet chosen ought to fulfil certain presentation necessities, including

shock absorption, resistance to penetration, and be customizable to fit and make agreeable to

the user. Absolutely the safety helmet can never be viable except if it is appropriately worn for

a reason.

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3.3 QUESTIONNAIRES DESIGN

In order to gather facts and information, a questionnaire is required. This part of the study

contains the details of the questionnaire used in the study. Two different questionnaires are

being used in this study. The details of their design are being discussed as follows.

3.3.1 FIRST QUESTIONNAIRE

The first questionnaire is the market survey, which is requested to get complete information

regarding the hard hats available, their prices, and their specifications.

The hard hats which were gathered from the literature review are the general hardhats from the

construction industry. These hard hats were further sorted out to find which are applicable for

the construction industry of Pakistan, which can view at Appendix A.

3.3.2 SECOND QUESTIONNAIRE

The second questionnaire is the labour survey to identify the problems of labourers while

wearing helmets and to understand the relationship between safety and protective headgear

system properly. The results collected by this survey were utilized to advance the headgear

system and provide safety parameters for the protection of labourers, which can view at

Appendix B.

3.4 DATA ANALYSIS AND COLLECTION

3.4.1 MARKET SURVEY

This survey is carried out from tools hub (house of hardware and tool) Warsi Market, Opposite

Katchi Gali no 3, Marriot Road Karachi.

Table 3.1 summarizes the helmets and their specifications as available in the local market, based on survey results.

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Table 3.1: Helmets and Their Specifications Used in the Local Market

3.4.2 LABOUR SURVEY

This survey report was gathered by means of a questionnaire and visiting site place (JPMC

Radiology LAB, JPMC mosque, Kings Classics. The questions were asked from skilled and

unskilled labourers and site engineers.

The first question asked during the survey was the age of labourers. The figure describes each

of the results as 38 % labours were between 18 to 28 years old, 20% were between 29-39, 30%

were between 39-49, and 10% were between 49-60 as shown in Figure 3.2.

Figure 3.2: Age of Labours

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HELMET NAME SPECIFICATIONS

EN 397 (INDUSTRIAL HELMET) Provide protection against high and low

temperature, electrical voltages up to 440V

Solar Powered Safety Helmet Hard

Ventilate Hat with Cooling Cool Fan

Ventilate and cooling

CHAPTER NO. 4

PROGRESS OF WORK

4.1 OVERALL PROJECT SCHEDULE/ TIMELINE

Insert your overall project timeline here distributed in months and identifying the key milestones. This should be in the form of a bar chart.

4.2 PROGRESS TO DATE

Insert sub-sections here to describe the project work done to date. This may be in the form of collection of data, compilation of results, description of results, illustration in the form of figures and tables, discussion, interpretation and compilation of key findings to date. This section is expected to be covered in 2-3 pages.

4.3 REMAINING WORK AND CHALLENGES

This section should indicate the work that remains to be done as per 4.1. Also, it should highlight the timeline of the remaining work and the challenges that are yet to be overcome.

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REFERENCES

Baabali. 2020. Smart Construction Helmets |Bluetooth Helmet. [online] Available at: www.babaali.co/smart-construction-helmet/?lang=zh-hans; [Accessed 21 October 2020].

DIY Air Quality Monitor with Sharp GP2Y1010AU0F Sensor. (2020). Retrieved 17 October 2020, from https://create.arduino.cc/projecthub/mircemk/diy-air-quality-monitor-with-sharp-gp2y1010au0f-sensor-7b0262

Zahoor, H. (2020). Construction safety research in Pakistan: A review and future research direction. Retrieved on 21 October 2020, from https://www.academia.edu/13342162/Construction_safety_research_in_Pakistan_A_review_and_future_research_direction

Hsu, Y.-L., Tai, C. Y., & Chen, T.-C. (2000). Improving thermal properties of industrial safety helmets. International Journal of Industrial Ergonomics, 27(1), 109–117.

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