Ah, hard hats. This is a requirement in most workplaces and a source of constant complaints among some professionals. However, not every design is uncomfortable. We've rounded up our team to share our recommendations for the coolest, most comfortable hard hats.
Before we get too deep, all of these hard hats have one thing in common: safety is the number one priority. Staying cool and comfortable isn't doing you any good if your PPE is compromising protection to give you. For safety reasons, we make Type II hard hats and helmets, which provide top and side impact protection, our top recommendation. We also have some Class I recommendations if you don't want or need maximum protection.
Is there a hard hat you like that we don't offer? Let us know your top picks in the comments below!
The Key to the Coolest, Most Comfortable Hard Hat
Vented vs. Non-vented Hard Hats
In the hard hat world, there are three main categories, vented and non-vented versions. Class C vented hard hats are conductive because the openings provide a path for the current to reach the head. Electricians must avoid these, for obvious reasons.
Class E non-vented hard hats are the way to go for electrical work. They are tested to 20,000 volts so they are effective even in high voltage areas.
The G category is more of a general purpose non-vented hard hat. These are not tested to the same high voltage standards as Type C, but they avoid openings that create electrical pathways.
The workplace where you are working will have specific rules about what is suitable. If you're allowed to wear a vented hard hat, you'll get the best cooling out of this style. Openings in the top allow heat to escape from your head and, in some cases, allow cool air to be blown through by a breeze.
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Hard hats have a suspension system that creates a barrier between the top of the head and the actual helmet. Some hard hats have a layer of foam between them for extra protection.
In general, more suspension points are more comfortable because it spreads the weight load better and reduces the stress on each point. Many hard hats have 4 point suspension. Look for 6 o'clock or higher for increased comfort.
weight
One of the biggest factors in hard hat comfort is weight. Not only does it affect how much pressure your head puts on the suspension point, but your neck muscles have to carry the extra weight throughout the day. Needless to say, the lighter model makes for a more comfortable hard hat.
WaveCel T2+ Max Type 2 Full Brim Hard Hat
While WaveCel's T2+ Max hard hat technically has a 4-point suspension system, that's its only downside. We say "technically" because the pad sits directly on the WaveCel material, so it distributes weight better than other 4-point systems.
It has a dial fit system with soft foam padding on the front and top of the suspension and rubber pads on the rear.
What makes it so different from the competition is WaveCel technology. Originally designed for riding (no, I haven't, yes, I want one!), it replaces the high-density foam protection with a contoured construction. By using this shape, it provides excellent protection while keeping the weight down to just 17 ounces and maximizing airflow.
Even the top vents are different from most. A series of side vents primarily facilitate heat escape, while large rear vents let the breeze blow over your head.
Even better, the WaveCel T2+ Max is proudly made in the USA.
- Type 2
- Class C exhaust
- 17 oz
- 4 point suspension
- WaveCel Protection System
- Lower profile reduces bumps
- WaveCel Accessory Rail
- Standard accessory slot
- Optional Chin Strap
- Dial Fit System with Vertical Height Adjustment
- 5 color options
- customizable
- made in America
If you need a Class E hard hat, WaveCel has you covered too. Look for the T2+ Pro as your Class 2, Class E non-vented option.
More recommendations for the coolest and most comfortable helmets
Milwaukee Type 2 Front Brim Safety Helmet
Milwaukee's Type 2 helmet options aren't as light as the WaveCel's, but they do an excellent job of promoting airflow. 26 individual vents in the top of the Class 2 version allow heat to escape and allow air to flow. Even if you're using grade E, the large cuts in the foam protector will leave a nice air gap.
- Type 2
- Class C vented (Class E unvented also available)
- 20 oz
- 4 point suspension
- Dial Adaptation System
- protective foam layer
- antibacterial lining
- With chin strap
- Compatible with BOLT accessories (including BOLT marker clip light bracket)
- 8 color options
- customizable
- Manufactured in the USA using global materials
- Also available without brim
MSA Super V Type 2 Fas-Trac III Hard Hat
MSA's Super V design is very popular. The V-shape at the top of the helmet helps deflect objects and provides more protection than a smooth shell. In terms of comfort, the MSA comes with 4-point suspension and doesn’t have as much padding as some of our other recommendations. However, it does have a front sweatband and rear rubber pads.
The main highlight is the Fas-Trac III design. It allows you to easily adjust the suspension's straps forward or rearward and has a simple dial mounting system. With its lower price tag, it strikes a balance between the luxurious comfort of our other recommendations and your PPE budget.
- Type 2
- Class E Non-vented
- 21 oz
- Fas-Trac III 4-point hitch
- Dial Adaptation System
- V-Gard deflects objects and adds protection
- Padded sweatband lining
- Compatible with standard accessories
- 5 color options
- customizable
The coolest and most comfortable type 1 hard hat
If you don't want or need the side-impact protection of a Type 2 hard hat, your options for the coolest, most comfortable hard hat widen considerably. Plus, they tend to be lighter and less expensive. Here are some of our favorites.
Milwaukee 6 Point Suspension Type 1 Full Brim Hard Hat
There are several reasons why Milwaukee's newest hard hat is one of the coolest, most comfortable Type 1 hard hats around. It starts with weight. At just 15 ounces, it's the lightest on our list, and that makes a big difference. It also features a 6-point suspension system, up from the 4-point suspension offered by the rest of the Milwaukee hard hat line. This model also offers a larger ratchet range than most, meaning it can accommodate more head sizes. Plus, the price tag is lower than our other top picks.
One downside is that the vents in this model don't promote airflow like some of the others on our list.
- Type 1
- Class C vented (Class E unvented also available)
- 15 oz
- 6 o'clock pause
- Dial Adaptation System
- Padded sweatband and top cover
- Bolt Fitting Compatible
- Includes BOLT reversible headlight mount and marker clip
- Compatible with standard accessories
- also available with front eaves
- 8 colors available
- customizable
- Manufactured in the USA using global materials
Bullard Cen10 Type 1 Safety Helmet
Bullard did a few things differently, specifically affecting the comfort of their Cen10 hard hats. Instead of using traditional suspension, foam inserts are used to distribute the weight. They also include a snug liner between the foam and your head, providing more cushioning than most hard hats.
The helmet itself has a sporty look and no brims. Currently, there are no front brim or full brim options, so keep that in mind if you prefer either.
- Type 1
- Class C vented (Class E unvented also available)
- 18 oz
- foam insert
- Dial Adaptation System
- With chin strap
- Padded sweatband and top liner
- Bullard accessories compatible
- Compatible with standard accessories
- 7 colors available
Klein Premium KARBN Type 1 Full Brim Hard Hat
Klein offers a wide range of hard hats and we really like their KARBN line. Beyond looks, they feature 6-point suspension, a padded sweatband covering the front and sides, a soft back pad, a padded hood, and even softer material on the chin strap. Vents cut into the sides promote airflow and can be closed for cold or rainy days.
Klein also has a rechargeable hard hat fan that you can add to their models. While it adds some airflow, it adds nearly 7 ounces to the weight. We haven't tested it to check the airflow for ourselves, and user feedback has been mixed. That said, it's a choice that sets the Klein hard hat apart.
- Type 1
- Class C vented (Class E unvented also available)
- 19 oz
- 6 o'clock pause
- Dial Adaptation System
- Padded sweatband and top cover
- softer chin strap
- Front and rear integrated headlight clips (available with or without headlights)
- Compatible with standard accessories
- Also available in safety helmet version