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CG634
CG634
CG634
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The CG634 is the main combat helmet of the Canadian Armed Forces. It was introduced in 1997 and is based on the French Gallet TC-3 helmet.[1] The helmet has protection equal to an NIJ Level 3a rating, being able to stop a shot from a .357 Magnum.[2]

Key Information

History

[edit]

The Canadian military sought a replacement for the steel M1 helmet in the 1980s. In 1984 it trialled the British Mk. 6, the American PASGT and the Israeli OR402 composite helmets to determine the best characteristics of form, fit and ballistic protection. A concept design was developed and the Barrday Co. of Cambridge, Ontario, received a contract to produce over 2,000 Spectra helmets between 1988 and 1990 for ballistic, engineering and user trials. While the Barrday helmet performed well ballistically, field trials identified significant shortcomings.

The Barrday contract was scrapped and the search for a new helmet resumed in late 1992. After testing a number of European off-the-shelf designs the process was completed in May 1996 and a contract to produce 60,000 helmets was issued to the French company Gallet, which produced the TC-3 helmet and its variants for the French, Danish and Austrian armies. From 1997 to 2004 the CG634 was manufactured by Gallet Sécurité Internationale Inc in Saint-Romuald, Quebec. Subsequent contracts were placed with MSA, which bought Gallet in 2002.[3]

Revision Military Inc (now rebranded as Galvion inc as of 2019 as they sold the eyewear branch along with the name) purchased the MSA Gallet factory that produced CG634 helmets from Mine Safety Appliances in 2012. They were awarded contracts to produce replacement parts and refurbish CG634 helmet shells during 2015-2020.

Design

[edit]

The CG634 is made of aramid (Kevlar) and has a minimum v50 of 634 m/s (compared to the PASGT's 610 m/s). It mates a modified French design, based on the PASGT, but adapted for compatibility with Canadian equipment (head-set, respirator, vision devices and armoured vest). The suspension system combines a thick foam trauma liner with a rubber and nylon webbing suspension based on the French Mle-78 (Gallet TC-3). The CG634 has a three-point chinstrap with flip-down adjustment pieces.[4] The CG634 was produced in 3 colours: green, black, and orange.

The CG634 has a somewhat similar shape and is sometimes mistaken for the later United States Army's MICH TC-2000 Combat Helmet. The MICH uses a foam padding system in its ground-combat helmet instead of webbing. The only pad system approved for use in combat is manufactured by Team Wendy and supplied by National Industries for the Blind.[5] These pads may also be used with the CG634.

When necessary, a night vision goggle mount is issued. The mount consists of a green metal bracket that hooks over the front of the helmet and the mount, which is screwed into it. There is a strap that loops through the mount and connects to a large ring, which is usually on the top of the helmet and two more straps secure the mount to the back of the helmet.[1] The mount is compatible with AN/PVS-7 and AN/PVS-14 night vision systems.[citation needed]

Accessories

[edit]

The CG634 helmet can be worn with a Camoflauge Cover in: CADPAT Temperate Woodland, Arid Regions, Artic/Winter Operations (CADPAT and plain white), UN Blue, UN Blue with markings, and black. As well as a Scrim Net and Camouflage Band.

Replacement

[edit]

The CG634 is scheduled to be replaced with the new CM735 combat helmet from Morgan Advanced Materials, which is based on their full-cut LASA AC914 for combat operations and the high-cut LASA AC915 for special operations.[6] As of 2019 NP Aerospace was due to supply the helmet over seven years.[7]

CM735

[edit]
CM735
A CM735 helmet
TypeCombat helmet
Place of originCanada
Service history
In service2016-Present
Production history
ManufacturerMorgan Advanced Materials 2015-2018
NP Aerospace 2018-2022
Produced2015-2022

In 2014 the Canadian military sought an interim replacement for the CG634 that would be the same shape as the CG634 helmet (minus the visor/lip), have interchangeable parts, and be lighter and have more ballistic resistance than the CG634. Morgan Advanced Materials won the contract for the Second Generation CG634 helmets after the LASA AC914 helmet designed using DSM Dyneema's UHMWPE ballistic fibre went through trials and was accepted. The CM735 helmet entered production in 2015 and began to be issued in 2016.

In 2019 NP Aerospace (formerly a part of Morgan Advanced Materials as NP Aerospace Ltd) was awarded a contract to produce CM735 helmets over 7 years, however helmet production has ended as of 2022.

Beginning in 2023 after trials in 2022, the Batlskin Caiman helmet under the designation Helmet High Cut Ground Troop's from Galvion Inc. is being issued in limited quantities to some units to replace CG634 and CM735 helmets as part of the Dismounted Infantry Capability Enhancement program.

The most noticeable difference between the CG634 and CM735 helmet is the lack of a visor/lip on the front of the CM735.

Users

[edit]

References

[edit]
Revisions and contributorsEdit on WikipediaRead on Wikipedia

CG634

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from Grokipedia
The CG634 is the primary combat helmet of the Canadian Armed Forces (CAF), designed to provide ballistic and impact protection for military personnel during operations. Introduced in 1997, it is constructed from aramid (Kevlar) fibers and offers a minimum V50 ballistic limit of 634 m/s, equivalent to NIJ Level IIIA protection capable of stopping a .357 Magnum round. The helmet's design is a modified version of the French Gallet TC-3, adapted from the U.S. PASGT helmet with a Canadian-developed suspension system featuring foam trauma padding and nylon webbing for comfort and stability. It includes a three-point chinstrap with adjustable flip-down buckles, compatibility with night vision goggles (via an AN/PVS-504 bracket), respirators, headsets, and CADPAT camouflage covers in variants such as Temperate Woodland, Arid Regions, and Winter Operations. Initially manufactured by Gallet Sécurité Internationale in Saint-Romuald, Quebec, from 1997 to 2004, production later shifted to MSA and subsequently Revision Military under ongoing contracts with the Department of National Defence. The CG634 emerged from trials starting in the 1980s, which evaluated prototypes including the British Mk. 6, U.S. PASGT, and Canadian Barrday Spectra helmets; over 2,000 Spectra units were tested between 1988 and 1990 before the Gallet-based design was selected for its superior ballistic performance and integration with CAF equipment. It succeeded the World War II-era M1 steel helmet and has been the standard issue for general forces, supporting parachuting and compatibility with armored vests. As of 2025, the CG634 remains the primary in widespread service, with gradual replacement underway through models like the CM735 for general forces and specialized helmets, such as the Batlskin and a new blast-mitigating prototype for , undergoing testing for enhanced protection against traumatic brain injuries. Recent procurements include additional Batlskin helmets for the Army in May 2025 and a new helmet contract for in January 2025 focused on brain injury prevention.

Development and History

Origins and Design Influences

The development of the CG634 helmet stemmed from efforts in the 1980s to replace the outdated steel with a modern composite design offering improved protection and compatibility with emerging equipment. Initiated under Project L1939 in , early trials in 1984 at Heals Range evaluated foreign models, including the U.S. PASGT helmet for its ballistic resistance and stability, the British Mk 6 for its harness comfort, and the Israeli OR402 for overall fit. These evaluations highlighted the need for a lightweight, modular that addressed shortcomings like poor respirator compatibility in the Mk 6 and vision obstruction in the PASGT, while prioritizing comfort during extended wear in peacekeeping operations. Subsequent field trials in 1989–1990 focused on the Canadian-developed Barrday P-1 and P-2 helmets, which demonstrated promising ballistic performance but faced issues with durability and production scalability, leading to their cancellation in 1992. This paved the way for an off-the-shelf acquisition strategy, culminating in the 1996 selection of the French Gallet TC-3 helmet as the base design. The CG634 adapted the TC-3's low-profile shape to reduce snag hazards and enhance , along with its ventilation features for improved airflow during prolonged use in varied environments. These modifications included a reduced peak height and wider side panels to better accommodate Canadian gear. Initial design goals emphasized balancing enhanced ballistic protection against fragments with significant weight reduction, targeting under 1.5 kg to minimize fatigue without compromising mobility. The helmet was also engineered for seamless integration with night vision devices like the , communication headsets, and the C4 respirator, ensuring modularity for accessories such as sights and masks. This focus on compatibility addressed feedback from trials, where foreign helmets often interfered with Canadian-specific equipment. Primary development was led by the French firm Gallet (operating as GSI Gallet Sécurité Internationale in ), which produced the helmet under license with localized adaptations to the suspension system for improved fit and retention. Manufacturing began in St-Romuald, , emphasizing aramid construction to meet these goals while aligning with standards for fragmentation resistance.

Procurement and Introduction

The procurement process for the CG634 by the Department of National Defence (DND) began in the early 1990s, following evaluations of prototype designs developed in the late , including a awarded to the for over 3,000 Spectra-based helmets between 1988 and 1990. Following the design selection in 1996, a was awarded to Gallet Sécurité Internationale for production of 60,000 units, commencing in 1997 at facilities in Saint-Romuald, . The CG634 was officially introduced and adopted by the Canadian Armed Forces (CAF) in 1997 as the standard-issue combat helmet, supplanting legacy M1-style steel helmets and prior experimental models like the Barrday P-1. This rollout marked a significant upgrade in personal protection, aligning with NATO interoperability requirements while incorporating Canadian-specific modifications for suspension, fit, and integration with national uniforms and gear. Initial production batches totaled approximately 60,000 units to equip active CAF personnel, reflecting economies from local assembly by Gallet Sécurité Internationale (GSI) until 2004. During procurement evaluations, the CG634 design was rigorously assessed to comply with NATO STANAG 2920 for ballistic fragment protection (V50 ≥ 634 m/s) and Canadian DND standards outlined in specification D-87-001-455/SF-001, including retention system strength (withstanding 5 kg drop loads with minimal deformation) and overall stability under load. These certifications ensured the helmet's suitability for frontline use, with production transitioning to Mine Safety Appliances (MSA) after 2004 to sustain supply.

Early Production and Testing

The CG634 helmet entered production in 1997 through a licensing agreement with the French firm Gallet, with manufacturing handled by Gallet Sécurité Internationale Inc. in Saint-Romuald, . This arrangement allowed for local production of the helmet, which was adapted from the Gallet TC-3 design to meet Canadian specifications, including a customized suspension system. Initial output focused on equipping units, with an estimated 60,000 units produced in the early years to fulfill needs. Ballistic testing for the CG634 was conducted at Defence Research and Development Canada (DRDC) Valcartier, adhering to protocols outlined in Department of National Defence specifications DND D-87-001-455/SF-001. These trials evaluated resistance to threats, including 9mm projectiles, confirming the helmet's equivalence to NIJ Level IIIA protection standards, which also encompass rounds. Environmental conditioning tests, incorporating low-temperature exposure to simulate Canadian climates, were integrated into the validation process alongside ambient, high-heat, and water immersion assessments to ensure performance under diverse conditions. During early evaluations, minor adjustments were made to the retention system's webbing and chinstrap configuration to improve fit and stability across head sizes, addressing feedback from trial wearers. Certification for operational use was granted in 1997 following successful completion of these protocols. By the late 1990s, production scaled to incorporate optional camouflage covers in the newly adopted pattern, enhancing the helmet's integration with Canadian uniform systems.

Design and Specifications

Construction and Materials

The CG634 helmet shell is constructed from (Kevlar 29) fabric, vacuum-formed and impregnated with resin for rigidity. The empty shell weighs approximately 1.4 kg and is produced in three sizes—small, medium, and large—covering head circumferences from 51 cm to approximately 66 cm, with built-in universal fit adjustments for accommodation across varying head shapes. Manufacturing entails hand-laying the aramid plies prior to curing for structural integrity, followed by application of a outer coating to enhance weather resistance. Integration of covers is standard, featuring Temperate or Arid patterns secured by elastic loops around the helmet's edge for quick attachment and removal. Later variants, such as the Gen II introduced in , feature minor improvements to the rim and padding while maintaining the original ballistic specifications.

Suspension System and Fit

The suspension system of the CG634 helmet employs a rubber and nylon webbing harness inspired by the French Mle-78 (Gallet TC-3) design, providing internal support for stability and comfort during wear. This webbing configuration attaches at multiple points within the shell, incorporating an adjustable chin strap with flip-down buckles and occipital support at the nape to secure the helmet against movement. The internal lining features a thick foam trauma liner composed of padded elements for impact absorption and user comfort, complemented by an integrated sweatband to wick away moisture. These are removable to facilitate and , ensuring in field conditions. Fit adjustments are achieved via strap-based and quick-release mechanisms on the and harness, allowing customization for various head shapes while maintaining compatibility with the C4 gas mask through headband extension. The helmet is produced in three sizes—small, medium, and large—covering head circumferences from 51 cm to approximately 66 cm, and is designed to accommodate balaclavas and cold-weather gear without compromising stability. Weight distribution is optimized by the chin strap's tension system, rated to withstand forces sufficient to prevent slippage under dynamic loads up to 30 kg equivalent during activities like running or jumping.

Ballistic and Impact Protection

The CG634 helmet achieves a ballistic rating with a V50 of 634 m/s against 17-grain (1.1 g) fragment-simulating lead projectiles (FSLAP) as defined under STANAG 2920, providing reliable protection against common fragmentation threats encountered in environments. This performance level aligns with the Canadian Department of National Defence's FG-B fragment protection category for current-generation helmets, ensuring a high probability of defeating low- shrapnel, effective against 1.1 g fragments up to its V50 of 634 m/s over key impact areas on the headform. Against threats, the CG634 meets NIJ Standard-0101.06 Level IIIA, capable of stopping 9 mm (FMJ) rounds with velocities up to 436 m/s, as well as .44 Magnum and .357 SIG projectiles. In terms of mitigation, the CG634 meets Canadian impact attenuation requirements of peak acceleration not exceeding 300 G during standardized drop tests at energies up to 60 J. Despite these capabilities, the CG634 provides no against rifle rounds, such as 5.56 mm or 7.62 mm , due to its soft shell design. It is also vulnerable to spalling on the inner surface in the absence of an anti-spall coating, potentially leading to secondary fragmentation injuries from back-face deformation upon impact.

Operational Use

Adoption by Canadian Armed Forces

The CG634 was adopted in 1997 as the standard protective headgear for the Canadian Armed Forces, replacing older steel helmets like the M1. Initial feedback from service members highlighted high acceptance of the CG634, particularly for its comfort and stability.

Combat Deployments and Performance

The CG634 helmet was extensively deployed by the Canadian Armed Forces during operations in Afghanistan from 2001 to 2014, where it served as the primary head protection for infantry and vehicle crews facing threats including improvised explosive devices (IEDs) and small arms fire. In counter-IED scenarios, such as quick reaction forces and urban patrols, the helmet provided critical coverage for exposed personnel like commanders and gunners operating with hatches open on vehicles including the LAV III and Coyote, mitigating head injuries from blasts and fragments in multiple engagements. It was also utilized in earlier peacekeeping missions in Bosnia and Kosovo, as well as domestic security operations. Performance evaluations from highlighted the helmet's effectiveness in real-world conditions, with after-action reviews noting its role in protecting against fragmentation in vehicle-borne IED incidents. A 2007 study of 28 soldiers found the CG634 helmet compatible for vehicle crew roles, though overall satisfaction was borderline acceptable. However, criticisms emerged regarding environmental limitations, including heat buildup in humid or dusty conditions. Despite these issues, the CG634 demonstrated reliable retention and stability under load, though some users reported neck chafing (affecting 50% of participants in compatibility tests) leading to minor adjustments in fit during extended wear. from deployed personnel underscores its life-saving potential, with the helmet credited in protecting against fragments in over a dozen reported incidents, aligning with its NIJ Level IIIA-equivalent ballistic rating for such threats. As of 2025, the CG634 continues in service for various CAF operations, including training and deployments, pending full replacement by the CM735.

Accessories and Modifications

The CG634 helmet is equipped with standard accessories designed to support night operations and identification. A prominent feature is the integrated night vision goggle (NVG) mount, compatible with devices such as the AN/PVS-14 monocular night vision system, enabling hands-free use during low-light conditions. This mount was included on later production models, such as those manufactured by MSA in 2008. For enhanced visibility and signaling, the helmet accommodates helmet-mounted lights like the MS-2000 strobe marker light, a (C-SAR) device used by military forces for distress signaling and identification under . This accessory attaches via or clips to the helmet cover, providing both visible and infrared (IR) strobe functions. IR reflective patches are also standard for (IFF) purposes, affixed to the helmet or cover to reflect under NVG for quick visual recognition in tactical scenarios. These patches are commonly integrated into gear for operational safety. Field modifications by users often focus on improving concealment and utility in diverse environments. Scrim netting, a mesh material in and tan variants, is attached to the helmet cover to disrupt the outline and blend with surroundings, particularly in arid or temperate zones like those encountered in deployments. Bungee cords are frequently employed for securing additional gear, such as pouches or sensors, to the helmet's exterior without compromising ballistic integrity. The helmet's design also ensures compatibility with hearing protection systems, such as the Peltor Comtac tactical headset, via rail or clamp adapters for comms integration. Similarly, it pairs with cold-weather hoods used in , accommodating layered cold-weather gear without impeding fit or protection.

Replacement and Legacy

Phasing Out and Successors

The Canadian Armed Forces initiated the phasing out of the CG634 in 2023 through the Dismounted Capability Enhancement () program, marking the start of a multi-year transition to advanced protective systems for dismounted units. This effort aligns with a broader 10-year contracting strategy launched in fiscal year 2023-24 to develop helmets offering enhanced protection against mild traumatic brain injuries (MTBI) from blasts, alongside improved ballistic performance to counter evolving threats such as higher-velocity small arms fire. Key drivers for replacement include the CG634's limitations in addressing modern operational demands, particularly in NVG compatibility and overall for night operations and communications, which the new designs prioritize for better soldier mobility and . The program specifically targets form, fit, and function improvements to enable full while carrying integrated gear like gas masks and electronics. Full fleet replacement under for is projected within 2025-2030. In parallel, a separate MTBI-focused helmet development project, including analog night-vision integration in Phase 1 (targeted for completion by 2026-27) and digital systems in Phase 2 (by 2031-32), is underway primarily for . The primary successor under DICE is the Galvion Batlskin ballistic helmet, selected after 2022 operational trials where it achieved the highest performance ratings among competitors for use. This (UHMWPE)-based system provides NIJ Level IIIA+ protection, exceeding the CG634's baseline V50 rating of 634 m/s for 9mm projectiles, while offering approximately 20% weight reduction (from around 1.47 kg to under 1.2 kg in medium sizes) to reduce neck strain and fatigue. It features modular rails for seamless NVG and headset mounting, along with customizable APEX padding for enhanced comfort. Initial procurement in February 2023 covered 2,100 helmets and 4,200 covers, followed by an 8,400-unit order in July 2024 and a 5,000-unit in July 2025, totaling over 15,500 helmets for delivery through early 2026. In parallel, is developing specialized blast-mitigating s, with initial deliveries expected in 2026 following blast testing conducted in September 2025 to address MTBI risks in close-quarters operations.

International Users and Exports

The has seen limited adoption beyond the Canadian Armed Forces, primarily through Canadian-led contingents in missions, where it is equipped with blue covers for identification as neutral forces. For instance, Canadian peacekeepers in various operations have utilized the CG634 under UN command structures, ensuring compatibility with international standards for observer and stabilization roles. Export efforts for the CG634 were pursued by manufacturer Gallet in the early , including at defense exhibitions like CANSEC, targeting potential sales to foreign militaries and organizations. However, no large-scale procurements by non-Canadian forces have been documented, with production focused predominantly on domestic needs. A specialized variant was produced for the (MFO) in the , featuring an orange exterior for enhanced visibility in monitoring duties. In joint operations, such as those in , allied forces occasionally shared equipment with Canadian units, but there is no verified record of temporary issuance of CG634 helmets to partners like or Dutch troops. Variations for export markets included customized covers adapted for environments, such as arid patterns, to suit operational theaters in warmer climates. Overall, international distribution remained modest, mainly to allied or observer groups.

Current Status and Evaluations

As of 2025, the CG634 helmet maintains a presence in the Canadian Armed Forces inventory, with approximately 30,000 units allocated to reserve and training roles following the cessation of new production in 2015. These helmets, originally procured in quantities exceeding 60,000 during initial manufacturing phases, continue to serve in low-intensity applications while frontline units transition to advanced models. A 2022 review by (DRDC) commended the CG634 for its proven durability in standard operations, attributing long-term structural integrity to its construction, yet highlighted its against contemporary high-threat environments, particularly and mild traumatic brain injuries. This assessment underscored the helmet's limitations in mitigating non-penetrative impacts, prompting accelerated adoption of next-generation protective gear for specialized forces. The CG634's legacy is marked by substantial contributions to soldier safety through enhanced ballistic resistance over prior steel designs. Its design influenced subsequent regional helmet standards, emphasizing improved fit and modular accessories that set benchmarks for NATO-aligned forces in the early . Looking ahead, surplus CG634 units face potential repurposing for civilian sales or placement in military museums, reflecting their historical role amid ongoing modernization efforts. This shift aligns with broader transitions to successors like the Batlskin , without disrupting reserve utility.

References

  1. https://servicebattalion.ca/museum-artifact/helmet-cg634-kevlar/
  2. http://mpmuseum.org/securhelmet.html
  3. https://www.defenceandsecurity.ca/media/article&id=348&t=m
  4. https://npaerospace.com/33m-canadian-ballistic-helmet-contract/
  5. https://ottawacitizen.com/news/national/defence-watch/canadian-military-new-helmet-special-forces-traumatic-brain-injuries
  6. https://www.facebook.com/groups/1068179394216912/posts/1417712432596938/
  7. https://globalnews.ca/video/11423024/exclusive-canadas-new-military-helmet-undergoes-blast-testing
  8. https://milart.blog/2013/08/27/canadas-search-for-a-composite-helmet/
  9. http://www.gostak.co.uk/composites/canada/
  10. https://biokinetics.com/wp-content/uploads/2024/04/Anctil-et-al-2008-The-Dev-of-a-Ballistic-Helmet-Test-Standard-PASS.pdf
  11. https://www.world-war-helmets.com/documentation/Canada/Canada_CG634_Canadian_forces_combat_helmet-User_manual.pdf
  12. https://www.militarytour.com/canadian-military-cg-634-kevlar-helmet-size-large-with-cadpat-cover.html
  13. https://canadabuys.canada.ca/en/tender-opportunities/contract-history/w8486-148836/001/pr-016
  14. https://hatchfive.wordpress.com/2020/07/24/canadian-cg634-helmet/
  15. https://www.herooutdoors.com/canadian-armed-forces-kevlar-helmet-cg634-medium/
  16. https://www.army.ca/forums/threads/new-suspension-for-cg634-helmet-not-so-good-for-jumping.86359/
  17. https://apps.dtic.mil/sti/tr/pdf/ADA515572.pdf
  18. https://shilostag.ca/ballistic-protection-important-for-soldiers-learning-from-afghan-war-experience/
  19. https://www.warrelics.eu/forum/ballistic-composite-helmets/canadian-cg634-balistic-kevlar-helmet-279539-5/
  20. https://www.acrartex.com/products/ms-2000-m2-strobe/
  21. https://www.mtlarmory.com/product-page/canadian-cg634-helmet-scrim
  22. https://militaryantiquestoronto.com/product/canadian-forces-cg634-kevlar-helmet-size-medium-with-cadpat-cover-and-scrim-net/
  23. https://www.canada.ca/en/department-national-defence/corporate/reports-publications/departmental-results-report/2023-24-index/results-core-resp/future-force-design.html
  24. https://www.canada.ca/en/department-national-defence/maple-leaf/defence/2025/05/contract-awarded-for-modernized-equipment-for-canadian-army-light-forces.html
  25. https://www.galvion.com/newsroom/galvion-receives-further-follow-on-caiman-order-of-5000-helmets-for-canada-dice-programme
  26. https://www.galvion.com/product/batlskin-caiman-tl
  27. https://apps.dtic.mil/sti/tr/pdf/AD1004167.pdf
  28. https://www.ebay.com/itm/386728964469
  29. https://www.galvion.com/newsroom/galvion-receives-follow-on-8400-batlskin-caiman-helmet
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