Cover of Predicting Head Injuries from Full-Scale Crash Tests
Predicting Head Injuries from Full-Scale Crash Tests
  • Publication no: AP-T383-25
  • ISBN: 978-1-922994-92-9
  • Published: 10 October 2025

This report reviews current literature and numerous existing full-scale crash test results to analyse trends in occupant impact measures and identify opportunities for further research into the relationship between these measures and actual injury outcomes.

The relationship between the Manual for Assessing Safety Hardware (MASH) occupant impact measures and the likely injuries is a constant discussion point when evaluating road safety barriers. This report consolidates findings from literature and crash tests to explore this relationship and highlight possible enhancements in the evaluation, design and installation of road safety barriers.

This report builds on the findings of Austroads Project ABT6152, which found that stiffer bridge parapets result in higher vehicle decelerations and may pose higher occupant risk than concrete road safety barriers.

While MASH limits are considered conservative, the extend of this conservatism is not well understood. For this report, vehicle trajectory was quantified using the Acceleration Severity Index (ASI), and likely head injuries were evaluated using the Head Injury Criterion (HIC) measured over 36 milliseconds. A regression equation was fitted to data from barrier impact tests conducted by Crashlab and those recorded in the literature.

The literature review indicates a correlation between ASI and HIC36, with evidence suggesting the relationship is likely exponential rather than linear. The report concludes that although ASI values above 2 may still meet MASH occupant impact and anthropomorphic test device (ATD) criteria, deployment decisions should consider the associated risk – particularly when installing bridge-parapet-like barriers on roadside.

  • Summary
  • 1. Introduction
    • 1.1 Purpose
    • 1.2 Background
  • 2. Occupant Risk
    • 2.1 MASH occupant risk criteria
    • 2.2 MASH requirements for using anthropomorphic test devices
    • 2.3 Head injury criterion
  • 3. Relationships Between HIC and ASI
    • 3.1 General relationships
    • 3.2 Relationships from sled tests
    • 3.3 Relationships from event data recorders
    • 3.4 Relationships from NCAP tests
    • 3.5 Relationships from simulated impact tests
    • 3.6 Relationships from full-scale impact tests
    • 3.7 Scaling factors for different occupants
    • 3.8 Concluding comment
  • 4. Full-scale Impact data
    • 4.1 Tests by Roads and Traffic Authority, NSW
    • 4.2 Austroads Project ABT6152
    • 4.3 Evaluation of HIC36 and ASI data
    • 4.4 Comparison of expected HIC36 results
    • 4.5 Is an ASI of 2.3 an anomaly?
    • 4.6 Consequences of higher HIC values
  • 5. Concluding Comments
    • 5.1 Application to design and barrier assessments
  • References
  • Appendix A Crash Summary Reports