Three measurements and two numbers
Three measurements taken with a tailor's tape over a thin T-shirt are enough for clothing:
- Chest circumference at the widest point, tape horizontal, arms relaxed at the sides, breathing relaxed.
- Waist circumference at the natural waistline above the hip, not over trouser waistband and not over a tool belt.
- Body height, without footwear.
Most manufacturers' size charts are based on these three measurements, making it possible to select both top and trouser sizes from them. Measuring one person takes only a few minutes.
Two figures are added separately. For safety footwear, the useful measurement is foot length in millimetres, taken at the end of a shift, when feet are usually somewhat larger, and while wearing the sock actually worn at work. Some manufacturers also state foot length in millimetres alongside the size number, which makes comparison between brands easier. If the team wears helmets, also add head circumference.
Gloves have their own scale, usually from 6 to 11, and are measured by hand circumference. The EN 388 marking on a glove indicates resistance to mechanical risks, not size.
Do not collect sizes by having everyone write down a letter themselves. The statement 'I wear L' tells you what someone last bought for themselves, not their chest circumference.
Why numbers 46 to 64 and letters S to 4XL do not match
Numeric sizes derive from the clothing size number. For a normal build, this is roughly half the chest circumference in centimetres: a circumference of around 100 cm gives size 50, a circumference of around 116 cm gives size 58. For trousers, the same number relates to waist circumference and body height.
For builds that deviate from the norm, manufacturers use special types of numbering. Short sizes are often marked with half the normal number, while long sizes are marked with a two-digit number in the range of roughly 90 to 110. This system is not uniform across all manufacturers, so check it in their size chart rather than guessing.
Letter sizes from S to 4XL are not an independent system. They are grouped labels for sets of numeric sizes, and the boundary between groups is set differently by each manufacturer. This means that XL from one manufacturer may be close to 2XL from another. This is not a product fault, but a difference between size charts.
The standard EN 13402 governs the size labelling of clothing and provides for the label to state body measurements in centimetres, usually with a pictogram, rather than the measurements of the garment itself. Where this pictogram is present, two size charts are comparable. Where only a letter is given, comparison is not possible. The use of this labelling is not mandatory for every product, so you will not find it on every label.
Women's cuts have their own basis: bust, waist and hips. Mixing up men's and women's size charts is a common reason for exchanges after delivery.
Workwear size reference chart
The table applies to men's cuts of normal build and is intended for rough team sizing, not for the final selection. It is compiled on the rule that the numeric size is roughly half the chest circumference, so it fits some manufacturers' tables better than others. Always check the final size in the manufacturer's table for the specific item.
| Letter size | Numeric size | Chest circumference (cm) | Waist circumference (cm) |
|---|---|---|---|
| S | 46 and 48 | 92 to 96 | 78 to 84 |
| M | 50 and 52 | 100 to 104 | 86 to 92 |
| L | 54 and 56 | 108 to 112 | 94 to 100 |
| XL | 58 and 60 | 116 to 120 | 102 to 108 |
| 2XL | 62 and 64 | 124 to 128 | 110 to 116 |
| 3XL | 66 and 68 | 132 to 136 | 118 to 124 |
| 4XL | 70 and 72 | 140 to 144 | 126 to 132 |
For workwear, the range often stops at 64 or 66. Larger sizes are usually only available in part of the range and may have a longer lead time.
How to collect measurements for 20 or 200 people
- One spreadsheet for everyone. Columns: name, department or shift, chest size, waist size, height, shoe size and foot length, notes.
- The notes column should capture anything that affects the choice: short or tall build, women's cut, need for trousers with pockets for knee pad inserts, known material sensitivity.
- Take measurements at one location during shift changeover, by department. A department of twenty people can be done in around one hour, while for two hundred people you should plan several sessions over several days.
- Sample garments should be on the table so people can check how the size from the table actually fits.
- Keep the list. For the next order, only measure new employees and those who report changes themselves.
Employee measurements are personal data. Collect only what you need for the order, keep it in HR records, and send the supplier only the total number of pieces per size, without names.
Sample pieces before a large order
Before placing a large order, order one piece of the main items in three or four sizes, typically M, L, XL and 2XL. Check the following:
- sleeve length when the arms are raised above the head
- whether the trouser leg rises above the top of the boot when crouching
- the height of the knee-pad pockets relative to the knee
- whether the jacket and trousers still cover the back when the person bends over
- how the item performs after the first wash at the temperature stated on the label, bearing in mind that industrial laundering is a different regime and should be checked separately
For high-visibility clothing under EN ISO 20471, the class is linked to the surface areas of fluorescent and reflective material on the item. The same model therefore does not necessarily achieve the same class in the smallest sizes as in the larger ones. Check the marking on the size you will be ordering, not just the model description. The same applies to other markings: EN ISO 20345 for safety footwear and EN 343 for rainwear relate to the specific product, not to the entire range.
Samples are also important because items with embroidery or printing are made to order and are generally not returnable. Check the supplier's terms for the specific order. The logo is applied to the garment only once the size has been confirmed.
Reserve: how many extra pieces to order
Split the reserve into three separate items.
- Replacements and damage: a common starting point is a few percent of extra pieces in medium sizes, where there are the most people and the most turnover.
- Edge sizes: XS, 3XL and above, as well as short and tall builds, are often made to order and have a longer delivery time. Order these in the first round, not the second.
- Staff turnover: look at how many people you have hired over the past twelve months, and keep roughly that many sets in reserve.
The number of sets needed per person per year is not a universal figure. It depends on the industry, the level of soiling, washing frequency, and whether you wash the clothing yourselves or rent it together with a laundry service. Note down how many pieces you actually replaced in the first year. This figure is more useful for your next order than any general table.
Once the measurements have been gathered, send the supplier a summary by size and item, together with notes on edge sizes. On this basis, the enquiry is specific, and delivery times for edge sizes are known in advance.
Three body measurements, two sizes for footwear and helmet, and one shared table are enough to compile an order for an entire team without guesswork. A letter on the label is not a common language; body measurements in centimetres are, so always check the size against the table of the manufacturer whose item you are ordering.