When PPE doesn’t fit, everyone pays

Personal protective equipment (PPE) is the frontline defence in construction and specialized transport. But fit matters. Recent regulatory shifts in the USA and rising awareness in Europe show that uniform sizing is no longer acceptable. Safety demands inclusivity.

In the UK, the #PPEthatfits campaign – led by the Chartered Institute of Building, alongside industry partners – has brought this issue into sharp relief.

Bouygues PPE partnership with OnSite Support includes a maternity range. Photo: Bouygues

Studies reveal nearly half of female engineers report ill-fitting trousers and overalls, with sizeable numbers of men, apprentices and larger workers facing similar issues. Ill-fitting PPE isn’t just uncomfortable; it creates new safety risks – from loss of mobility to gear getting caught in machinery – or failing to protect vital areas properly.

In the USA the Occupational Safety & Health Administration (OSHA) has taken decisive action. In December 2024 it finalised a long-awaited update – effective January 2025 – requiring PPE in construction to “properly fit” each worker. This aligns construction standards with those already in place for general and maritime industries. OSHA acknowledges an improper fit can leave workers vulnerable to hazards – or discourage use altogether.

Cited examples include hard hats that slip, oversized gloves that impede grip and harnesses that don’t distribute fall forces correctly. OSHA, its advisory committee and worker advocates like unions and safety organisations, overwhelmingly support the update.

That said, clarity is emerging. OSHA emphasises a performance-based approach: PPE must fit and not introduce fresh risks, without prescribing exact sizing. This model respects diversity in worker physiques while aligning with manufacturers’ standards.

Europe isn’t far behind. UK vocational providers and standards bodies – backed by #PPEthatfits – are working to introduce new guidelines and standards for inclusive protective gear. Pilot “taster weeks” and toolkits are already helping reshape a more inclusive safety culture.

A clear message

As for SC&RA’s international membership and audience, this shift suggests a rethinking of PPE procurement. Standard “one-size-fits-most” is no longer sufficient. Employers should partner with suppliers who offer inclusive sizing and designs that truly “fit.” That means expanding beyond hard hats and boots – consider gloves, harnesses, eyewear and coveralls. In cross-border operations, national standards and local regulations may vary – but safety remains universal.

Second, test for fit on-site. Simple measures – like fit trials, comfort surveys and feedback loops – can help identify problem areas before incidents occur. Encourage workers of all backgrounds to speak up about equipment that doesn’t work for them, without stigma.

Third, share best practices globally. If US contractors are educating crews on fit-based safety or European firms are piloting female-tailored harnesses or tools, bring those lessons into project toolboxes. SC&RA’s international network is uniquely positioned to spread what works across borders.

Inclusive PPE isn’t about political correctness – it’s operational excellence. Embracing it can reduce injury risk, boost adoption rates and improve workforce diversity. It signals that every team member matters – not just on paper, but on the jobsite. If nothing else, the message is becoming clear: “proper fit” is now a legal requirement in key markets. More importantly, it’s a strategic advantage. Committing to inclusive PPE designations demonstrates leadership in safety and culture.

By ensuring our tools and protection work for every body, we build safer, stronger teams – whether lifting a tower crane in Germany or moving an industrial transformer in Canada. Proper fit in PPE is about more than compliance; it’s about respect, performance and a commitment to excellence that spans borders.