Hard Hat Sizes UK: Choosing the Right Fit for Safety

A hard day of work and demanding clients can be stressful enough, don’t let a poorly fitted hard hat add to the discomfort. 

Finding the right hard hat size is essential for both comfort and safety. In the UK, hard hat sizes are based on head circumference, which you can determine using a measuring tape. Once you have your measurement, refer to supplier size charts to choose the correct fit.

A properly fitted hard hat should sit snugly without being too tight, ensuring stability and comfort throughout your workday. Many brands offer adjustable suspension systems, allowing for a customised fit that prevents slipping or discomfort.

Beyond size, consider material quality and safety standards to ensure maximum protection. Understanding different hard hat types, safety ratings, and adjustability options can help you purchase the hard hat that meets your workplace requirements.

Understanding Hat Sizes in the UK

Hat sizes in the UK can differ from those used in other parts of the world, making it essential to measure your head correctly for the right fit.

To determine your size, wrap a measuring tape around your head, approximately 1 to 2 centimetres above your ears, ensuring a snug but comfortable fit. This measurement, taken in centimetres, serves as the basis for UK hat sizing. If you don’t have a measuring tape, use a piece of string or any flexible, non-adhesive tape, then measure it against a ruler.

Understanding these conversions makes shopping for headwear easier, whether online or in stores.

Here’s an adult hat size chart showing head circumferences in different units:

Keep in mind that different brands may have different sizing charts and if you’re in between sizes, it’s best to get in touch with the store for expert guidance or choose an adjustable hard hat. 

A hard hat with a secure fit should sit comfortably on your head, staying in place without slipping or causing discomfort as you move. Essential Workwear’s safety hats are designed to provide both comfort and reliability, featuring a fully adjustable, one-size-fits-all design to ensure the perfect fit without fuss.

Types of Hard Hats & Their Fit

1. Cap-Style vs. Full-Brim Hard Hats

• Cap-style: The most common type, featuring a short front brim.
• Full-brim: A full brim helmet offers 360-degree protection, ideal for outdoor jobs exposed to sun and rain.

2. Vented vs. Non-Vented Hard Hats 

• Vented: Improves airflow and reduces heat buildup.
• Unvented: Offers better electrical insulation, ideal for electricians.

3. Bump Caps vs. Hard Hats

• Bump caps: Designed for low-impact areas, like warehouses.
• Hard hats: Required in high-risk environments like construction sites and heavy industry.

Hard Hat Adjustability Features

A secure fit is important for both comfort and protection. Look for:

1. Ratchet Adjustments: Quick and easy size adjustment.
2. Chin Straps: Keeps the hard hat secure in high-wind or high-movement environments.
3. Sweatbands & Padding: Prevents discomfort during long shifts.

Common Hard Hat Sizing Mistakes & Solutions

Wearing a beanie underneath without adjusting the fit: This can cause an improper fit.

• Solution: Use a winter liner designed for hard hats.

Using a deteriorated hard hat: Materials degrade over time.

• Solution: Replace hard hat every 3-5 years or after a major impact.

Choosing the wrong fit: A loose or tight fit reduces protection.

• Solution: Always adjust the suspension system for a secure but comfortable fit.

UK Hard Hat Safety Standards

All hard hats sold in the UK must meet EN 397, the British Standard for industrial helmets. This regulation ensures protection against:

• Impact resistance (protecting against falling objects).
• Penetration protection (sharp objects puncturing the shell).
• Chin strap strength (for additional security).
• Electrical insulation (for low-voltage protection in specific models).

For high-risk environments such as working at height, some helmets meet EN 12492, which provides additional protection for climbers and rescue workers.

As a BSIF Registered Safety Supplier, Essential Workwear ensures that all our hard hats and safety equipment meet these rigorous standards. Our commitment to quality and compliance guarantees that you receive genuine, certified products designed to protect lives and meet workplace safety regulations.

Using and Maintaining Hard Hats

Proper use and regular maintenance are essential to ensure hard hats provide maximum protection on-site. Follow these key guidelines for wearing, inspecting, maintaining, and replacing your hard hat in compliance with HSE (Health and Safety Executive) safety regulations. To learn more about hard hat safety standards, check out our detailed blog post on the topic.

How to Wear a Hard Hat Correctly

• Always wear your hard hat with the brim facing forward to shield against falling objects.
• Adjust the suspension system for a snug, level fit. It shouldn’t be too tight or too loose.
• Never modify or alter your hard hat, as this can weaken its protective capabilities.

Inspection and Maintenance Tips

1. Daily Checks: Inspect for cracks, dents, or any damage before wearing.
2. Suspension System: Check for signs of wear or fraying and replace if damaged.
3. Impact Damage: If your hard hat sustains a strong impact, replace it immediately, even if there’s no visible damage.
4. Cleaning Guidelines: Wash with mild soap and warm water, then dry thoroughly before use. Avoid harsh chemicals that could weaken the plastic.
5. Sticker Placement: Stickers should be kept to a minimum and must not cover cracks or damage-prone areas.

When to Replace and Dispose of a Hard Hat

Replace your hard hat:

• If damaged, cracked, or after a heavy impact.
• As per manufacturer recommendations (usually every 3-5 years).

Proper Disposal:

• Do not throw hard hats into general waste.
• Look for recycling programs or industrial waste disposal services.

Always buy replacement hard hats from reputable suppliers to ensure they meet HSE safety standards and pass mandatory impact tests. 

Final Thoughts

Selecting the correct hard hat size is essential for ensuring both protection and comfort on the job. Measuring your head circumference, understanding UK sizing standards, and choosing a properly fitted safety helmet will help prevent discomfort and enhance safety.

Beyond size, consider factors like adjustability, ventilation, material quality, and compliance with BS EN 397 safety standards. Regular inspection, maintenance, and timely replacement are also crucial to keep your hard hat in peak condition.

Whether you’re working in construction, manufacturing, or high-risk industries, investing in a high-quality, well-fitted hard hat ensures you stay protected throughout your workday.

Frequently Asked Questions

1. What is the difference between Type 1 and Type 2 hard hats?

Type 1 hard hats are designed to protect against blows to the top of the head and Type 2 helmets offer protection against both lateral and vertical impacts. Lateral protection is useful in environments where side impacts might occur.

2. Which factors contribute to the comfort of a hard hat?

Key comfort factors include adjustable suspension systems, sweatbands, and adequate ventilation. Materials and weight also influence comfort. Picking a helmet that suits your head shape and job requirements is essential for long-term wearability. 

3. Can I customise my PPE hard hat with stickers or paint?

Stickers should be kept to a minimum and must not cover cracks or damage-prone areas. Painting is advised against, as some chemicals can weaken the material and reduce impact resistance. If your company or team requires customised hard hats, Essential Workwear offers a variety of options for your safety helmets or hard hats, including detailed logos or designs in your chosen colours and styles.