A cowboy hard hat is an industrial hard hat molded in the shape of a western hat, with a creased crown and a wide brim all the way around. Inside, it uses the same suspension as a standard hard hat, and models from safety manufacturers are tested to ANSI/ISEA Z89.1, the standard OSHA points to for head protection.
They are also called western hard hats or outlaw hard hats, after one of the first models on the market. This guide covers how they are built, the styles and materials you will see, who wears them, and their limits.
How a cowboy hard hat is built
A cowboy hard hat has the same three working parts as any hard hat:
- The shell. A rigid outer shell, molded to look like a cattleman or pinch-front cowboy hat. It spreads the force of a falling object and resists penetration.
- The suspension. A harness of 4 or 6 straps that holds the shell about an inch above your head. That gap is what absorbs the energy of a strike. Most cowboy hard hats use a ratchet headband that you adjust with a knob at the back; some use a pin-lock band.
- The sweatband. A replaceable brow pad, usually terry cloth or foam, that clips to the front of the headband.
The fourth part you should always find is the label, printed or embossed inside the shell. It lists the manufacturer, the date of manufacture, the ANSI Z89.1 designation, the Type and Class, and the head size range. A hat without that label is a costume, not head protection.
What is a cowboy hard hat style? The common shapes
| Style | What it looks like | Worth knowing |
|---|---|---|
| Cattleman crown | A tall crown with a center crease and two side dents, like a classic felt work hat. | The most common shape. Usually Type I, Class G or E. |
| Pinch-front crown | A crown pinched at the front into a teardrop shape. | A popular vintage-style look. Same ratings as cattleman models. |
| Vented crown | Vent openings near the top of the crown. | Cooler, but vents remove electrical protection, so vented models are Class C. |
| Patterned finish | Printed finishes such as carbon fiber weave, wood grain, camo or flags. | Usually a printed or dipped finish on a plastic shell. Check that the finish is applied by the manufacturer. |
Materials
Most cowboy hard hats are made from high-density polyethylene (HDPE). It is light, takes an impact well and keeps prices low, which is why most models sell for roughly $30 to $80. Other shells use ABS plastic or fiberglass, which handles heat better. A few premium models use carbon fiber composites to save weight.
Whatever the material, the rating on the label matters more than what the shell is made of. A well-made HDPE hat with the right Type and Class is better protection for your job than an expensive shell with the wrong rating.
Who wears cowboy hard hats
- Ranch and farm crews working around equipment, chutes and overhead hazards, who also want shade.
- Oil and gas field workers, where western-style hard hats have been common for decades on sites that accept them.
- Construction supervisors and inspectors on sites that allow Type I hard hats.
- Surveyors, landscapers and utility crews who spend long days in the sun.
- Visitors and managers touring plants and job sites that require head protection.
Why people choose them
Shade. The brim on a cowboy hard hat is usually wider than a standard full-brim hard hat. That keeps more sun off your face, ears and neck and sheds rain away from your collar.
People keep them on. Supervisors have long said that a hat workers like is a hat workers wear. A hard hat only protects you when it is on your head, and many people would rather wear a western shape than a dome.
It fits the work. For ranch and oilfield workers who wear a cowboy hat everywhere else, a western hard hat is the natural choice when the job calls for head protection.
Limitations
- Mostly Type I. Nearly all cowboy hard hats are rated for top impacts only. Sites that require Type II (top and side impact) will not accept them.
- Accessory fit. Many models have no accessory slots, so standard earmuffs, face shields and some lights will not attach.
- Wind and tight spaces. A wide brim catches wind and can knock against ladders, pipe racks and ductwork. A chin strap helps in wind.
- Site rules. Some employers and general contractors do not allow brimmed or western-style hats at all, regardless of rating. We explain the rules in our guide to wearing one on a construction site.
How to tell a real one from a novelty hat
Party stores and online marketplaces sell plastic “hard hat” cowboy hats that look similar but have no rating. Before you buy, look for the ANSI Z89.1 designation with a Type and Class in the product details, and check for it inside the shell when the hat arrives. If you cannot find it, do not wear it to work. Our guide to cowboy hard hat ANSI ratings explains every marking on the label.
For more on styles, ratings and fit, start at our cowboy hard hats hub.
Sources
Frequently asked questions
Are cowboy hard hats real hard hats?
Yes. Cowboy hard hats from safety manufacturers are tested to the ANSI/ISEA Z89.1 standard, usually as Type I with Class G or Class E electrical protection. Novelty versions without an ANSI label are not hard hats.
What are cowboy hard hats made of?
Most are high-density polyethylene (HDPE). Some use ABS plastic, fiberglass or carbon fiber composites. The suspension inside is a 4- or 6-point strap harness with a ratchet or pin-lock headband.
What is another name for a cowboy hard hat?
They are also called western hard hats, western-style hard hats and outlaw hard hats, after one of the first models sold.
How much does a cowboy hard hat cost?
Most certified cowboy hard hats sell for roughly $30 to $80. Carbon fiber and custom-printed models cost more.