PM/ IS 4151/ 1/ January 2019

PRODUCT MANUAL FOR

PROTECTIVE HELMET FOR TWO WHEELER RIDERS
ACCORDING TO IS 4151: 2015
This Product Manual shall be used as reference material by all Regional/Branch Offices &
licensees to ensure coherence of practice and transparency in operation of certification under
Scheme-I of Bureau of Indian Standards (Conformity Assessment) Regulations, 2018 for
various products. The document may also be used by prospective applicants desirous of
obtaining BIS certification licence/certificate.

1. Product : IS 4151 : 2015

PROTECTIVE HELMET FOR TWO WHEELER
Title :
RIDERS
No. of Amendments : 1

2. Sampling Guidelines:
a) Raw material : Materials - Clause 4 of IS 4151 : 2015
Each variety of helmet shall be tested to cover that variety
b) Grouping guidelines :
in the licence
c) Sample Size : 8 Helmets - for all tests

3. List of Test Equipment : Please refer ANNEX – A

Scheme of Inspection
4. : Please refer ANNEX – B
and Testing

5. Possible tests in a day :

(i) Sizes (Clause 5)
(ii) Constructional requirement (Clause 6.1 to 6.6))
(iii) Peripheral vision (Clause 6.7)
(iv) Workmanship and Finish (Clause 6.8)
(v) Mass (Class 6.9)
(vi) Dynamic test of retention system (Clause 7.5)
6. Scope of the Licence :
“Licence is granted to use Standard Mark as per IS 4151 : 2015 with the following scope:
Name of the product PROTECTIVE HELMET FOR TWO WHEELER RIDERS
- With or without lower face cover
Type
- With or without Visor
Size --- mm
BUREAU OF INDIAN STANDARDS
Manak Bhawan, 9, Bahadur Shah Zafar Marg,
New Delhi – 110002
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 PM/ IS 4151/ 1/ January 2019

ANNEX A

List of Test Equipment

Major test equipment required to test as per the Indian Standard

S. No. Tests used in with Clause Test Equipment

Reference
1 Metal parts (Clause 4.5) - Spray cabinet
- Temperature controlling arrangement
- Salt spray arrangement under pressure and with
atomizer
- Solution collection device
2 Visor (Clause 4.6) a) Impact Resistance
- Test apparatus
- Air conditioner
- Steel spherical ball
b) Penetration Resistance
- Test apparatus
- Pointed project with 50 gm weight
c) Flammability
- Burner
- Bare copper wire 0.71 mm
- Protractor
- Stop watch
d) Spherical and cylindrical error and Prismatic
error
- Standard lenses
- Telescope
- Adjustable light source with condenser
e) Diffuse transmittance and Light Transmission
- Haze meter
- Integrating sphere
f) Mass
- Weighing balance with weights
3 Sizes (Clause 5) Head forms of various sizes as per Annex A of
IS 4151
4 Shell (Clause 6.2) - Vernier calliper / Steel scale
- Radius gauges

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5 Retention system - Vernier calliper

(Clause 6.4) - Load of 150 N ± 5 N
6 Peripheral vision - Head forms of various sizes
(Clause 6.7) - Load of 50 N
- Angle protractor or gauge to check the angle
7 Mass (Clause 6.9) - Weighing balance
8 Impact absorption test - As per C-2 of IS 4151
(Clause 7.2)
9 Rigidity test -
Loading arrangement on helmet with loads of 630
(Clause 7.3) N and 30 N
- Steel scale or Vernier calliper
- Stop watch
10 Test for projections and surface friction (Clause 7.4)
Method A - As per E-1.2 of IS 4151

Method B - As per E-2.2 of IS 4151

11 Dynamic test of - Test apparatus
retention system - Headform with 15 ± 0.5 kg mass
(Clause 7.5) - Falling mass 10 ± 0.1 kg and height 750 ± 5 mm
12 Audibility test - As per G-1 of IS 4151
(Clause 7.6)
13 Retention (Detaching ) - Retention (Detaching) test apparatus
test (Clause 7.7) - Headform
- Falling mass of 10 ± 0.01 kg from height 0.50 ± 0.01 m
height
14 Micro-slip test of the - Apparatus for testing slippage of the chin strap
chin strap (Clause 7.8) - Reciprocating clamp
15 Test for resistance to - Apparatus for testing abrasion of the chin strap
abrasion of the chin
strap (Clause 7.9)
16 Tests for retention system relying quick – release mechanisms (Clause 7.10)
Inadvertent release by Rigid sphere of 100 mm and load to exert pressure of
pressure (Clause 7.10.1) 100 ± 5 N on helmet
Ease of release - Force measuring equipment
(Clause 7.10.2) - Dynamometer
- Vernier calliper

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Durability of Quick – - Suitable test apparatus

release Mechanisms - Provision for applying force of 20 ± 1 N
(Clause 7.10.3) - Closed cabinet with spray arrangement and
temperature control arrangement
17 For conditioning of helmets (Clause 7.1.1)
Solvent conditioning - Cotton cloth
(Clause 7.1.1.1) - Octane
- Toluene
- Stop watch
- Steel scale
Ambient temperature and - Arrangement for maintaining temperature of
hygrometry conditioning 25 ± 5 ° C and humidity 65 ± 5 %
(Clause 7.1.1.2)
- Stop watch
Heat conditioning - Arrangement for maintaining temperature of
(Clause 7.1.1.3) 50 ± 5 ° C
- Stop watch
Low temperature - Arrangement for maintaining temperature of
conditioning - 20 ± 2 ° C
(Clause 7.1.1.4) - Stop watch
Ultraviolet –radiation - Xenon filled quartz lamp of 125 W with range
conditioning and moisture 25 cm
conditioning - Water spraying arrangement
(Clause 7.1.1.5)
- Timer

The above list is indicative only and may not be treated as exhaustive.

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ANNEX B

Scheme of Inspection And Testing

1. LABORATORY - A laboratory shall be maintained which shall be suitably equipped (as

per the requirement given in column 2 of Table 1) and staffed, where different tests given in
the specification shall be carried out in accordance with the methods given in the
specification.

1.1 The manufacturer shall prepare a calibration plan for the test equipments.

2. TEST RECORDS – The manufacturer shall maintain test records for the tests carried out
to establish conformity.

3. LABELLING AND MARKING – As per the requirement of IS 4151: 2015.

3.1 In addition, if visor is provided with the helmet, it shall be marked with manufacturer’s
name or trade mark, year of manufacture and identification in code or otherwise for
traceability.

3.2 Each visor shall also be tagged with a printed card having the following information:
a) To maintain a good field of vision, formation of scratches and accumulation of dirt on
the visor screen shall be avoided.

b) No organic solvents or materials containing organic solvents such as metal polish, wax
and polish shall be used to clean the visor screen.

c) A soft cloth shall be used to wipe the visor for removing dust, dirt etc.

4. CONTROL UNIT – Helmets of same shape and size manufactured under similar
conditions in a day shall constitute a control unit.

5. LEVELS OF CONTROL - The tests as indicated in column 1 of Table 1 and the levels of
control in column 3 of Table 1, shall be carried out on the whole production of the factory
which is covered by this plan and appropriate records maintained in accordance with
paragraph 2 above.

5.1 All the production which conforms to the Indian Standards and covered by the licence
should be marked with Standard Mark.

6. REJECTIONS – Disposal of non-conforming product shall be done in such a way so as to

ensure that there is no violation of provisions of BIS Act, 2016.

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TABLE 1

(1) (2) (3)

Test Details Test equipment Levels of Control
Cl. Requirement Test Method requirement No. of Sample Frequency Remarks
Clause Reference R: required (or)
S: Sub-contracting
permitted
4.1 Shell 4.1 IS 4151 – – – Material shall conform to the
4.2 Protective padding 4.2 IS 4151 – – – requirements.

4.3 Comfort padding 4.3 IS 4151 – – –

4.4 Retention system 4.4 IS 4151 – – –
4.5 Metal Parts 4.5 IS 4151 S Two samples Each No further testing is required if
(Corrosion IS 9844 for each consignment accompanied with the test certificate.
resistance) component. However, random sample counter
check on each component may be
carried out once in three months.
4.6 Visor 4.6 IS 4151 R One sample Each lot No further testing is required if
and (If provided) IS 9973 for each shape accompanied with the test certificate
6.1.2 and size or ISI marked. However, for non-ISI
visors, random sample counter check
may be carried out once in a month.
5 Sizes 5.1 IS 4151 R Eight Each control In case of any failure, all helmets in
unit the control unit shall be tested.
6 CONSTRUCTIONAL REQUIREMENTS
6.1 General 6.1.1 , IS 4151 R Eight Each control In case of any failure, all helmets in the
(Except visor) 6.1.2 unit control unit shall be tested
6.1.3
6.2 Shell 6.2.1 to IS 4151 R Eight Each control
6.2.7 unit
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6.3 Protective padding 6.3 IS 4151 R Eight Each control In case of any failure, all helmets in the
unit control unit shall be tested
6.4 Retention system 6.4 IS 4151 R Eight Each control –
unit
6.5 Characteristics of 6.5 IS 4151 R Eight Each control –
material of helmet unit
6.6 Safety of wearer 6.6 IS 4151 R Eight Each control –
unit
6.7 Peripheral vision 6.7, IS 4151 R One sample for each shape and # Please see foot note.
Annex B size from every 7 control units.
6.8 Workmanship and 6.8 IS 4151 R Each – –
finish
6.9 Mass 6.9 IS 4151 R Eight Each control In case of any failure, all the helmets in
unit the control unit shall be tested.

7.2 Impact absorption 7.1, 7.2, IS 4151 S Five samples Once in three # Please see footnote.
test Annex C for each shape months
and size
7.3 Rigidity test 7.1, 7.3, IS 4151 R Two samples for each shape # Please see footnote.
Annex D and size from every 30 control
7.4 Test for 7.4, IS 4151 R units # Please see footnote.
projections and Annex E
surface friction
7.5 Dynamic test of 7.5, IS 4151 R One Each control -
retention system Annex F unit

7.6 Audibility test 7.6, IS 4151 S One sample Once in 6 # Please see footnote.
Annex G for each shape month
and size

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7.7 Retention 7.1, 7.7, IS 4151 R One sample Each control

(Detaching) test of Annex H unit –
helmet
7.8 Micro-slip test of 7.8, IS 4151 S One sample Once in three # Please see footnote.
the Chin strap Annex J for each shape month
and size
7.9 Test for resistance 7.9, IS 4151 S One sample Once in three # Please see footnote.
to abrasion of the Annex K for each shape month
Chin strap and size
7.10 Test for retention 7.10 IS 4151 S One sample Once in three # Please see footnote.
systems relying on for each shape month
quick release and size
mechanisms

# In case of failure of sample in any of the requirements as per clauses 6.7, 7.2, 7.3, 7.4, 7.6, 7.8, 7.9 and 7.10, samples from two
consecutive control units shall be tested for the requirement in which failure has occurred. The original frequency shall be restored only after
samples from both control units are found meeting the requirement.

Note-1: Sub-contracting is permitted to a laboratory recognized by the Bureau or Government laboratories empanelled by the Bureau.

Note-2: The control unit and levels of control as decided by the Bureau are obligatory, to which the licensee shall comply with.