To adjust a hard hat suspension, set the crown straps to the right height, tighten the headband with the ratchet knob or pin-lock until it’s snug, and position the nape strap below the back of your head. The hat should stay in place when you nod and look down, without pressure points.
Parts of a hard hat suspension
- Crown straps: the 4 or 6 woven straps that cross over the top of your head and hold the shell above it.
- Keys or clips: plastic tabs that lock the suspension into slots in the shell.
- Headband: the band that goes around your head, with a sweatband at the front.
- Adjuster: a ratchet knob or a pin-lock at the back.
- Nape strap: the lower back part of the headband, sometimes adjustable up and down.
Step 1: Check the suspension is installed correctly
Every key should be fully locked into its slot, with the sweatband at the front (or at the back if the hat is marked for reverse wear and you have reversed it per the instructions). A loose key can let the shell shift on impact.
Step 2: Set the crown height
Many suspensions let you move the crown straps to raise or lower the hat. Set it so the headband sits just above your eyebrows and ears, with clearance between your head and the top of the shell. Never remove straps or cut them shorter.
Step 3: Adjust a ratchet suspension
- Loosen the ratchet fully. On most hats you push the knob in and turn it counterclockwise.
- Put the hat on with the brim level.
- Turn the knob clockwise until the band is snug.
- Release the knob so it locks in place.
Step 4: Adjust a pin-lock suspension
- Take the hat off and unhook the pin from its hole.
- Move the band to a smaller or larger hole.
- Press the pin through until it clicks.
- Try it on and repeat until it’s snug.
Step 5: Position the nape strap
If the back of the headband adjusts up and down, set it below the bulge at the back of your skull. This keeps the hat from tipping forward when you look down.
Step 6: Test the fit
- Nod and look down: the hat stays put.
- Shake your head: the hat moves with you.
- Wear it for a few minutes: no headache or pressure points.
When to replace the suspension
Replace it if straps are frayed, stretched or stiff, if keys are cracked, if the ratchet slips, or at the maker’s recommended interval, often about 12 months. Use only the suspension made for your hat. See when to replace a cowboy hard hat.
For western-style hats, the cowboy hard hat sizing and fit guide adds tips for wide brims and wind. More on the hard hats hub.
Sources
- International Safety Equipment Association (ANSI/ISEA Z89.1)
- OSHA 29 CFR 1910.132, PPE general requirements
Frequently asked questions
How do you tighten a ratchet hard hat?
Push the ratchet knob in and turn it clockwise until the headband is snug, then release it to lock.
How high should a hard hat sit on your head?
The headband should sit just above your eyebrows and ears, with clearance between the top of your head and the inside of the shell.
Can I use a different brand suspension in my hard hat?
No. Use only the suspension made for your hat. A different one can change how the hat performs and may void the rating.