Providing well-fitting PPE is not optional; it is a legal responsibility that directly affects worker safety, morale, and performance. Poor-fitting PPE doesn’t just reduce protection; it creates new hazards and signals to workers that they were not considered in safety planning – especially for women and workers with smaller or non-standard body sizes.
Workers today are more diverse than ever in age, gender, and body size. When PPE doesn’t fit:
- It causes discomfort and limits mobility
- It increases injury risks
- It leads to non-compliance or unsafe modifications
Conversely, inclusive PPE helps to:
- Reduce injuries and time-loss claims
- Lower insurance premiums
- Increase compliance and productivity
- Support retention and recruitment
Concerning Report Findings
In 2022, the CSA Group published the Canadian Women’s Experiences with PPE report. The findings
revealed:
- 58% of women wore the wrong size PPE.
- 28% skipped required PPE due to fit.
- 40% reported injuries tied to poor PPE fit.
- Many resorted to DIY fixes like duct tape, safety pins, or altering fall harnesses—a dangerous
safety violation.
PPE that doesn’t fit isn’t PPE — it’s a hazard.
The Evolving Workforce and Inclusive Design
The construction site is an ever-changing environment, and the workforce is evolving along with it. Today, many sites employ workers who fall outside outdated standards of what the “typical” construction worker looks like. You now see people of all ages, genders, and body sizes in the field.
However, most “unisex” or “one-size” PPE is still based on the proportions of a man who is 5’10” and 180–200 lbs — a standard that no longer reflects the diversity of modern job sites. Many men and women on site do not fall within this range, making inclusive PPE not just a need, but a priority.
Unisex or male-designed PPE also fails to account for key anatomical differences – women generally have more weight distribution in the hips and thighs, whereas men are typically broader in the chest and shoulders.
These differences affect how PPE fits and performs:
- Coveralls designed for men may pull tightly across the hips but sag at the shoulders for women.
- Harnesses may ride up uncomfortably or unsafely on smaller torsos. Workers have been
restitching harnesses to make them fit. These repairs will fail during a fall, which is a lifethreatening risk - Pants or bibs may restrict movement or cause chafing in the thighs or waist area.
- Vests and jackets may gape at the chest or restrict the armhole area.
- Gloves and boots are often oversized for women, increasing issues of snagged clothing and
tripping.
What’s Missing Today?
Getting properly fitting PPE should not be such an issue for so many workers – yet it’s hard to find small footwear sizes in most industrial catalogues and fall protection gear is often too big to fit smaller frames safely. Currently in Canada, women must sign up for a waitlist 6 months long to get gear that fits properly. PPE standards don’t reflect the wide range of body types in today’s diverse workforce. Additionally, many employers still use outdated, one-size-fits-all programs that do not provide proper protection for everyone.
What Employers Must Do
- Assess Fit – Not Just Function
PPE should be evaluated for fit, comfort, and usability, not just hazard protection. - Offer Multiple Sizes and Cuts
Provide PPE in a wide range of sizes and body-specific cuts. Look for designs specifically made for women and smaller bodies. - Listen and Involve Workers
Consult with affected employees before procurement. Fit testing should be standard. - Stop Modifications Immediately
DIY fixes (rethreading harnesses, taping gear) are unsafe. Provide compliant options instead. - Update Your PPE Program
Include gender, body size, and inclusive design in regular program reviews. - Stay Current with Regulations
Occupational health legislation increasingly recognizes the importance of proper PPE fit across all demographics. Stay compliant and proactive.
Remember, PPE isn’t effective if it isn’t designed for your body. The best PPE is the one workers will wear—properly.