How to Assemble a Hard Hat

Updated February 21, 2017

Hard hats are a requirement on all professional construction job sites. It is a good practice to wear one for home projects as well. Hard hats protect you from injury in the event of falling objects. Trying to figure out how to assemble a hard hat can bring frustration, as instructions are often missing from the hard-hat package. Follow a few basic steps to install the harness quickly and fit your hard hat correctly.

Place your hard hat upside down in your lap with the small moulded brim (the front) facing away from you.

Pull the web suspension out from the plastic head band of the hard hat harness so the web suspension hangs down in the middle of the band. Make sure that no webbing wraps around the head band or goes over the outside of the band. Turn the head band so the ratchet or tab adjustment strip is facing your body (this is the back of the head band).

Place the head band into the hard hat. Align the centre of the back of the band with the centre of the back of the hard hat.

Pull the plastic tabs moulded into the outside of the head band into their matching tab holders (moulded into the inside the hard hat). If you have centred the head band correctly, the tabs and holders will line up. There will be four of them, two at the front of the hard hat and two at the back.

Put the hard hat on your head and adjust the sizing. If you have a ratchet-style head band, turn the ratchet clockwise to tighten the band and counter-clockwise to loosen. If you have a tab-style adjustment band, it will work like the adjustment on a baseball cap. Pull the band until the hard hat fits well. Lock the tabs through the slotted band to hold it in place. A hard hat should be comfortable to wear, but you should be able to bend your head as if looking at the ground without it falling off.


Wrap a handkerchief around the front of your hard hat harness to act as a sweat band. Hard hats can be uncomfortable to wear, particularly in hot weather, but they are necessary and a sweat band will help make one easier to wear.


Hard hats have a limited lifespan. Replace yours immediately should it become cracked, if the plastic appears faded, or if you have passed the date stamped on the inside of the brim. Your hard hat will not be able to protect you in the event of an accident.

Things You'll Need

  • Hard hat harness (ratchet or tab)
  • Handkerchief
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About the Author

Cassandra Tribe has worked in the construction field for over 17 years and has experience in a variety of mechanical, scientific, automotive and mathematical forms. She has been writing and editing for over 10 years. Her areas of interest include culture and society, automotive, computers, business, the Internet, science and structural engineering and implementation.