FEATURE FIT-FIRST THINKING


PPE that fits properly is fundamental to workplace safety, and employers must prioritise comfort, usability and inclusivity alongside compliance, says Adam Evans of ABUS UK & Ireland.


Interim findings from GMB’s PPE Fit for All campaign found that two-thirds of workers have experienced problems with incorrectly fitting PPE. Workers reported using equipment that was too large, too small or unsuitable for their body shape, while some had purchased their own PPE or altered standard issue equipment to achieve a better fit.


These findings highlight a challenge extending across many industries. PPE that does not fit properly can compromise protection, restrict movement, reduce comfort and create distraction, increasing risk.


For employers, the findings present an important reminder that PPE provision is about more than compliance. Equipment may meet the relevant standards, but if it does not fit the individual wearing it, its effectiveness is significantly reduced. As organisations continue to strengthen workplace safety cultures, ensuring PPE is fit for both purpose and person must become a greater priority.


Attention is increasingly turning towards how PPE performs in real working environments, where usability, comfort and inclusivity are becoming as significant as technical specification. Equipment is now being judged on whether it passes certification and whether it can be worn correctly and consistently throughout a working day.


THE REALITY OF PPE FIT IN EVERYDAY WORK


In sectors such as construction, manufacturing, logistics and utilities, PPE is worn continuously in physically demanding environments. Gloves, helmets, safety boots, high-visibility clothing and respiratory protection are not occasional safeguards but constant working tools. When any element of that equipment does not fit correctly, the impact is immediate and cumulative.


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Poor fit emerges through repeated friction in daily tasks, from reduced dexterity that slows handling, to footwear creating pressure during long shifts, or helmets that shift with movement and require constant adjustment. These issues gradually influence how tasks are performed, increasing fatigue and reducing concentration over time.


Where discomfort persists, workers naturally adapt their behaviour. PPE is adjusted more frequently, worn loosely in certain situations or removed briefly during tasks where it feels restrictive. In some cases it is not worn at all. Over time, these issues introduce inconsistency and delays into environments that depend on operational efficiency.


WHERE PPE SYSTEMS FAIL TO MATCH REAL WORKING CONDITIONS


Although PPE is governed by strict regulatory standards, those standards assess protective performance in controlled conditions rather than how equipment functions across the full diversity of users in practice. This creates a structural gap between compliance and real- world effectiveness.


Compliance confirms equipment meets a defined safety threshold, but it does not guarantee suitability for all body types, movement patterns or working durations. As a result, PPE can perform well in testing while still proving uncomfortable or impractical in sustained use.


This gap is reinforced by how PPE is typically selected and supplied. Many organisations streamline procurement by standardising ranges across large workforces, prioritising efficiency in purchasing and distribution. While this approach simplifies logistics, it reduces flexibility in fit, sizing and design variation, leaving some workers with limited alternatives.


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