A uniform order can look straightforward until the sizes arrive. Too-small polos restrict movement, oversized hi-vis can create safety issues, and one inconsistent size run can leave staff looking less professional than intended. Knowing how to choose uniform sizes before you upload your logo and approve the proof helps you avoid unnecessary exchanges, delays and repeat orders.
For most UK businesses, the best approach is not to guess from everyday clothing sizes. Build your order around the garment’s own size guide, the job staff need to do and a simple way to collect measurements from the team.
Start with the garment, not the label size
A medium is not a universal measurement. A medium polo from one workwear brand may fit closer than a medium hoodie from another, while a unisex jacket may have a different cut again. This matters particularly when you are mixing garments across a full uniform order, such as polos, sweatshirts, softshells, work trousers and hi-vis layers.
Always check the size chart supplied for the exact garment you are ordering. Look for the body measurement the garment is designed to fit, rather than relying only on the garment’s flat measurements. Chest size is usually the key measurement for T-shirts, polos, fleeces, jackets and hoodies. Waist and inside leg matter most for work trousers and shorts.
If a size chart gives a chest range, choose based on the wearer’s actual chest measurement and allow for the intended use. A fitted front-of-house polo and a site jacket worn over a sweatshirt should not be selected in the same way.
Decide how the uniform needs to fit at work
The right size is about more than appearance. Your team needs to be able to work comfortably through a full shift, whether they are serving customers, lifting materials, driving between jobs or working outside in poor weather.
For hospitality, retail and office-facing roles, a neater fit often gives the smart, consistent look businesses want. Staff should still be able to reach, bend and move comfortably, especially in roles involving carrying trays, cleaning or stock handling. Polo shirts, shirts, aprons and lightweight knitwear are commonly chosen closer to the wearer’s normal fit, provided the size guide supports it.
For trade, facilities and outdoor teams, allow room for movement and layering. A softshell or waterproof jacket may be worn over a polo and hoodie, so ordering it too close can make it uncomfortable in colder months. Work trousers should allow for kneeling, climbing ladders and moving tools in and out of pockets without pulling across the waist or thigh.
Hi-vis clothing needs particular care. It should be large enough to sit properly over the layers beneath it without covering the wearer’s movement, but not so loose that it snags on equipment or catches in machinery. Where PPE requirements apply, check that the garment type and fit are suitable for the work being carried out.
How to choose uniform sizes using real measurements
The most reliable method is to ask each team member for a measurement, not just a preferred size. It takes a little more organisation at the start, but it is far quicker than handling several exchanges after a branded order has been produced.
For tops and outerwear, measure around the fullest part of the chest with the tape held level and comfortably close to the body. Do not pull it tight. For trousers, measure the natural waist where the wearer normally sits their work trousers, then measure the inside leg from the crotch seam to the desired hem length.
Ask employees to measure over light clothing where possible. If they will regularly wear layers underneath, they should account for that when selecting outerwear. A person who usually wears a large T-shirt may need an extra-large softshell if it is intended to go over a hoodie.
It is helpful to collect the information in one simple format: employee name, garment, colour, required size and any fit note. A fit note can cover practical points such as “needs longer leg”, “wears over jumper” or “prefers a relaxed fit”. This is particularly useful when ordering a mixture of garments for different roles.
Use sample garments where the order is larger
If you are outfitting a growing team or placing a larger first order, try to check sizing with one or two unbranded samples before committing the full order. This is especially worthwhile for jackets, trousers, chefwear and garments with a more structured or specialist fit.
A sample allows staff to test shoulder room, sleeve length, waistband comfort and movement. It can also confirm whether your chosen logo position works well on the garment. The small amount of planning can prevent an entire team receiving sizes that technically match the chart but do not suit the cut.
If samples are not practical, compare the supplied size guide with a garment that already fits the employee well. Measure that garment flat across the chest, waist or inside leg and use it as a reference, while remembering that different fabrics and cuts will still vary.
Plan for unisex, women’s and specialist fits
Many workwear garments are sold in unisex sizing. This keeps ordering simple and works well for a wide range of teams, but it may not suit every wearer equally. Unisex cuts can feel broad in the shoulders or long in the body for some staff, while others may prefer the extra room.
Where available, offering a women’s fit alongside a unisex option can improve comfort and presentation. The key is to make this an individual choice rather than assuming a fit based on someone’s gender. Share the relevant size guide for each cut and let staff select the option that works best for them.
Specialist garments need their own checks. Chef jackets should allow arm movement and comfortable fastening through a busy service. Aprons need suitable neck and waist adjustment. Safety footwear, gloves and hard hats must be selected according to their specific measurement and protection requirements, not an assumed clothing size.
Avoid common uniform sizing mistakes
The most expensive mistake is ordering every item in the same size for each person. Someone may wear a medium polo, large hoodie and extra-large waterproof because each item has a different fit and is worn in different conditions.
Another common issue is ordering only the most popular sizes and hoping the spread will work. This can be tempting when issuing a quick starter pack, but it often leaves new employees without suitable clothing. If you need spare stock, keep a small range of common sizes after measuring the core team rather than using stock as a substitute for individual sizing.
Avoid sizing down to achieve a sharper look. Uniforms that feel restrictive are less likely to be worn properly, and tight fabric can put extra strain on embroidery, printed areas, seams and fastenings. Equally, do not automatically size up across the board. Excess fabric can look untidy and may interfere with practical tasks.
Finally, do not overlook shrinkage and care instructions. Quality workwear is designed for regular washing, but cotton-rich garments can change slightly if washed hotter than recommended or tumble dried aggressively. Share the care guidance with staff, particularly for embroidered polos, printed T-shirts and branded hoodies.
Build sizes into your ordering process
A consistent process makes future uniform orders much easier. Keep a private record of approved sizes for each employee, including the garment brand or style. When a new starter joins, use the same form and size guide rather than asking them for a vague small, medium or large.
For recurring orders, note any changes staff report after wearing the garments for a few weeks. Perhaps the fleece sleeves run long, a particular trouser style is generous at the waist, or your team prefers a roomier fit in winter. These details make the next order quicker and more accurate.
When ordering through Bolt Uniforms, send your size breakdown with the garment choices and logo artwork, then review the digital proof before production begins. The proof confirms your branding and placement, while your size list ensures each person receives a garment that is suitable for their role.
A well-sized uniform is one staff can put on without thinking about it - comfortable enough for the workday, smart enough for customers and consistent enough to represent your business properly. Take the extra few minutes to measure first, and your team will feel the benefit every time they start a shift.