How often should sun hats be replaced?
Written by
Kiana Okafor
Reviewed by
Prof. Charles Hartman, Ph.D.Sun hats have limited longevity in UV blocking performance, which requires consideration for replacement timing. Even in a worn condition, with appropriate usage, the skin can be exposed to dangerous UV radiation. Most regularly used hats should be replaced every 2-3 seasons, depending not only on usage and projection, but also on the degradation of the UV-blocking material due to sun exposure and repeated washing/drying. Ultimately, it is up to the wearer to recognize the signs of failure.
Visual Changes
- Fading colors show UV-blocking treatments breaking down
- Thinning fabrics develop light-permeable weak spots
- Discoloration indicates material breakdown from sweat and sun
Structural Damage
- Brims losing shape compromise coverage angles
- Stretched sweatbands create gaps allowing radiation
- Broken chin straps reduce stability in windy conditions
Performance Decline
- Reduced water resistance in rain hats
- Slower drying times indicating fiber breakdown
- Decreased airflow despite clean ventilation panels
My Tilley hat had a good run, lasting five seasons before I had to replace it. After over 200 hikes in the desert sun, I noticed the crown had begun to fade slightly in color. I believe that wearing a premium brand hat can extend its lifespan even further before replacement; however, all premium hats eventually require replacement. You generally start to see some wear even with budget hats after 20 outdoor uses, but they're inexpensive.
The frequency at which you wash your headwear has a direct correlation with when you need to replace it. Machine washing significantly degrades UPF treatments more quickly than hand washing headwear. Always follow the care labels to be safe, but generally, cold water works well below 30°C (86°F). After 50 wash cycles of even the best hats, the original protection has diminished significantly.
The climate can dictate how urgent you need to replace gear. Humid areas can accelerate the breakdown of a material. At the same time, places with low humidity can cause colors to fade more quickly. Areas with salt air, such as coastal communities, can cause the metal parts on adjustable hats to corrode. Having a schedule for replacing items based on the local climate is a good policy.
When considering a replacement, consider whether warranty coverage applies. Premium brands, like Sunday Afternoons, offer no-hassle replacement for manufacturing defects. Budget choices rarely include coverage for normal wear and tear. Rather, consider purchasing based on long-term protection value, knowing replacement costs are built into the overall value.
Read the full article: Ultimate Hat Sun Protection Guide
