How to put together a hard hat?

Q: I’m a construction worker and I need to buy some PPE for my work, I’d like to know how to put together a hard hat.

– Alex Pieter

A: Assembling a hard hat involves putting together various components, including the shell, the suspension system, and sometimes additional accessories like a visor or earmuffs. Here’s a general step-by-step guide on how to put together a hard hat:

Step 1: Inspect the Components
Before assembly, ensure all parts of the hard hat — the shell and the suspension system — are free from damage. Any signs of cracks, tears, or excessive wear mean the part should be replaced.

Step 2: Attach the Suspension
The suspension system typically consists of straps and a headband.

  • Lay the hard hat shell upside down.
  • Insert the suspension system into the shell. The headband part of the suspension should be at the brim of the hat.
  • You will see slots on the inside of the hard hat shell where the suspension system fits. Insert the suspension’s key (the little plastic or metal piece at the end of the strap) into the slot. Do this for all keys and slots. The number of keys and slots will depend on the specific design of the hard hat.

Step 3: Adjust the Suspension
Once the suspension system is attached, adjust the headband so it fits comfortably on your head. Most hard hats have a ratchet system or a pin lock system for adjustment.

  • For a ratchet system: Turn the knob at the back of the hard hat until the headband fits snugly but comfortably.
  • For a pin lock system: Similar to a belt, move the pin to the appropriate hole on the band to adjust the size.

Step 4: Add Accessories (If Needed)
If you have accessories like a visor or earmuffs, attach them according to the manufacturer’s instructions.

Step 5: Final Check
Try on the hard hat. It should fit snugly but comfortably. The brim should be at the forehead level, and the hat should not wobble or slip off easily.

Remember, for safety equipment like hard hats, always follow the manufacturer’s instructions for assembly and use. If the hard hat suffers a heavy impact, replace it immediately, even if no damage is visible. Regularly inspect your hard hat for signs of wear and tear or damage.

Have a question about personal safety equipment, work clothes, PPE industry? Anbu Safety writer Arlen Wang will find answers to the queries. to submit a question send an email to:

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