Design and Implementation of a GSM-based IoT Smart Safety Helmet for Construction Workers

The construction industry is recognized as one of the most hazardous occupational sectors, particularly in developing countries, where workplace accidents frequently result in serious injuries and fatalities. Falls from height, exposure to toxic gases, extreme environmental conditions, and inadequate supervision at remote sites are among the most common risks faced by construction workers. In most cases, personal protective equipment offered is usually inadequate, especially in the case of remote locations where construction supervision is not available. In light of these issues, this study proposes an IoT-based smart safety helmet intended for construction workers. The proposed system is designed with the ESP32 microcontroller as its core combining several sensors, such as the MPU6050 accelerator and gyroscope to identify falls, the DHT22 sensor to monitor temperature and humidity, the MQ-2 gas sensor to detect hazardous gases, and the NEO-6M GPS module to track real-time location. Remote construction sites are often devoid of Wi-Fi or cloud service and the proposed system relies on a GSM module for data transmission. The sensor data are sent to a web dashboard in ThingSpeak, based on the HTTP protocols, and the critical conditions cause the multi-channel alerts with the use of the onboard buzzer, dashboard notifications, and SMS messages to site managers. Experimental results demonstrate that the proposed helmet provides accurate real-time monitoring and dependable data transmission. The design of the helmet enhances its practicality and efficiency, especially in construction settings where workplace hazards and the risk of accidents are prevalent by merging low-cost, lightweight, and dependable communication technologies.