A polo shirt that pulls at the shoulders or work trousers that catch when kneeling will not stay in the uniform cupboard for long. Knowing how to size workwear properly helps your team look professional, move freely and get proper value from every garment you order.
Sizing is not simply a case of picking the size someone usually wears on the high street. Workwear has to suit the job, the season, the garment brand and, in many cases, the layers worn underneath. A little planning before personalisation avoids unnecessary reorders and gives your staff uniforms they are happy to wear.
Why workwear sizing needs more thought
A good uniform should support the work being done, not restrict it. A front-of-house polo may need a neat, closer fit, while a tradesperson's hoodie or softshell must leave room to reach, bend and layer up. Kitchen teams need chef jackets and aprons that allow movement in a hot environment, whereas cleaning and facilities teams may need practical, easy-care garments worn over their own clothes.
There is also a brand consideration. Uniforms look more consistent when each person has the right fit, even if the team wears a mix of sizes and garment styles. Clothing that is too large can look untidy and may create snagging risks around equipment. Clothing that is too tight wears out faster at stress points and can make a long shift uncomfortable.
The best approach is to size for the role and the individual, rather than ordering every item on the assumption that it will fit like a standard T-shirt.
How to size workwear before placing an order
Start with the manufacturer's size guide for the exact garment you have chosen. A medium is not universal. Measurements can vary between brands and even between a regular-fit polo, a ladies' fit polo and a heavy-duty sweatshirt from the same supplier.
Ask each team member to provide their chest, waist and, where relevant, inside leg measurement. Measurements should be taken over light clothing, without pulling the tape too tight. For jackets, fleeces and outer layers, account for what will normally be worn underneath.
The most useful measurements are:
- Chest: measure around the fullest part of the chest, keeping the tape level.
- Waist: measure around the natural waist or the point where work trousers will sit.
- Inside leg: measure from the crotch seam to the preferred trouser length.
- Hips: particularly useful for fitted trousers, shorts and ladies' styles.
- Height and build: helpful when deciding between regular and tall leg lengths, or when a garment is likely to be worn as an outer layer.
For a new team uniform, it is worth ordering or trying on unbranded samples first where possible. This is particularly useful for larger orders, mixed teams or garments with a more structured cut, such as work trousers, chef jackets and hi-vis outerwear. A quick fitting session is often faster and less costly than guessing across twenty or thirty people.
Choose the larger size when movement matters
If someone falls between sizes, the right choice depends on the garment and the job. For a smart polo worn in a café, reception area or retail setting, the closer size may be suitable if it still allows full shoulder and arm movement. For hoodies, fleeces, jackets and hi-vis clothing, sizing up is often the sensible option when the item will be worn over a T-shirt, sweatshirt or base layer.
Do not rely on a garment feeling acceptable while standing still. Ask the wearer to lift both arms, bend forward, sit down and, for trade workwear, kneel or squat. If the hem rises sharply, the back feels tight or the sleeves pull, move up a size or consider a different fit.
Match the fit to the garment and the job
Different workwear categories need different fit checks. A polo shirt should sit comfortably across the chest and shoulders, with enough length to stay tucked in if required. T-shirts can be slightly more relaxed, especially for physical work or warm environments.
Sweatshirts, hoodies and fleeces should accommodate the layers likely to be worn underneath. A close-fitting fleece can work well as a mid-layer, but a hoodie used as the main outer garment usually needs more room. Consider this before adding embroidery, as a heavily stretched garment can make the logo area sit less neatly.
Softshells and jackets need room through the shoulders and back. Check that zips close comfortably over a polo or sweatshirt and that sleeves are long enough when arms are extended. A jacket that fits perfectly over a T-shirt may be too restrictive on a cold morning when layered over a hoodie.
For work trousers, focus on waist, rise and leg length rather than the label size alone. The wearer should be able to crouch without pulling at the seat or thighs. A slightly long leg can be a trip risk or drag in wet conditions, while a short leg can leave the ankle exposed when kneeling. Where regular and long leg options are available, use the inside leg measurement rather than making a rough judgement from height.
Hi-vis garments require the same practical fit, but there is an added safety consideration. They must be visible, correctly fastened and not so loose that they snag. If hi-vis is being used alongside harnesses, tool belts or other PPE, test the full combination before committing to a larger order. Branded PPE should always be selected with the relevant safety requirements and intended use in mind.
Make sizing easier for a mixed team
A single unisex garment range can simplify ordering, but it will not suit every team equally well. Offering a choice of unisex and ladies' fits can improve comfort and appearance, particularly for office, hospitality and customer-facing staff. The same applies to trousers, where a choice of waist and leg measurements gives a far better result than a small, medium and large-only range.
Keep a simple size record once staff have confirmed their fit. Record the garment name, brand, colour, size and leg length, not just “medium” or “large”. This makes repeat orders far easier when a new starter joins or an existing team member needs a replacement.
It also helps to separate essential uniform from optional layers. For example, a plumbing team may all need the same branded polo and trousers, while hoodies, gilets and waterproof jackets can be ordered according to individual preference and seasonal needs. This keeps costs controlled without forcing everyone into a garment they will rarely use.
Avoid the common sizing mistakes
The most frequent mistake is ordering from memory. Someone may wear a large in one retailer and an extra-large in a workwear brand. Always use the specific size guide and check the fit of the selected style.
Another issue is forgetting about shrinkage and wash care. Quality workwear is designed for regular laundering, but garments should still be washed according to their care label. If your team works in environments where high-temperature washing is necessary, select garments suited to that wash regime and discuss it before ordering.
Avoid assuming that a size exchange will be straightforward once a logo has been added. Personalised garments are produced for your business, so confirming sizes before embroidery or printing is the safest route. A digital proof confirms your logo placement and appearance, but it does not confirm garment fit. Treat sizing approval as a separate check.
Finally, do not overlook seasonal changes. A lightweight branded T-shirt may be the right summer uniform, but the same team may need a larger fleece, softshell or waterproof for winter layering. Planning both options together creates a more consistent uniform range and reduces last-minute orders when the weather turns.
A practical ordering process for team uniforms
For a small team, send each employee the size guide for the chosen garments and collect measurements or confirmed sizes before checkout. For larger teams, run a brief fitting session with sample garments and appoint one person to maintain the size record.
When selecting branded workwear, choose garments first, then confirm colours, sizes and quantities by role. Upload your logo and review the digital mock-up carefully before production begins. Bolt Uniforms can help with garment selection and flexible size combinations, which is useful when you need one consistent logo across polos, hoodies, jackets and hi-vis clothing without imposing one fit on the whole team.
The right workwear size is the one your staff can work in comfortably, wear with confidence and reach for at the start of every shift. Take the extra few minutes to measure, test movement and check each garment guide before personalisation - your team and your uniform budget will both benefit.