Wrong Sizing Is the Most Avoidable Problem in Workwear Orders
Every workwear supplier, including us at Customised Workwear, deals with size-related returns and exchanges. Staff receive their garment and it doesn’t fit. Sometimes it’s too small, sometimes too large. Occasionally, the embroidery on a non-standard fit means a simple exchange isn’t possible without reordering.
Almost all of these situations are avoidable. The solution is a simple, standardised sizing process run with your team before the order is placed. Here’s exactly how to do it.
Understanding Workwear Sizing Systems
Most UK workwear uses standard S/M/L/XL sizing, but the actual measurements behind these labels vary significantly between garment brands and styles. A size L from one manufacturer fits differently from a size L from another. This is why we always recommend referencing the specific size chart for the garment you’re ordering rather than assuming sizes are universal.
All garments in our workwear shop include full size charts with chest, waist, and length measurements. Use these — don’t guess.
How to Run a Team Sizing Exercise
The most accurate way to size your team is a simple measuring exercise. You’ll need a fabric tape measure and five minutes per employee. Measure:
- Chest: Under the arms, across the fullest part of the chest. For polo shirts and jackets, add 5–8cm to the measured chest for a comfortable workwear fit.
- Waist: Natural waist, relevant for trousers and some jacket styles.
- Height: For length-critical garments like jackets and trousers.
Record every team member’s measurements in a simple spreadsheet. Cross-reference against the garment size chart and assign a recommended size to each person. Send the size assignments to each employee for confirmation before placing the order.
Fit Considerations by Garment Type
Polo shirts and t-shirts: For most roles, a relaxed fit (one size up from measured chest) is most comfortable for a full working day. For customer-facing hospitality roles, a closer fit looks more professional.
Fleeces and softshells: These are worn over base layers. Size up one from your polo to allow comfortable layering without restricting movement.
Jackets: Allow for two layers underneath. Size up accordingly, particularly for outdoor trade roles where full arm movement is essential.
Typical Sizing Distribution for UK Teams
As a rough planning guide for mixed-gender UK teams: XS 5%, S 10%, M 25%, L 30%, XL 20%, 2XL 8%, 3XL 2%. This will vary by industry and team demographics, but it’s a useful starting point for estimating quantities before your sizing exercise is complete.
Order a Pre-Production Sample
For orders over 20 pieces, always order one sample garment first. Have your staff representative try it on. Confirm the fit is right for your team’s typical body type and working environment. Only then place the full order.
Browse our full workwear bundles with size guides, or contact us for sizing advice before you order.