4 December 2025
fit testing explained: why it’s more than just compliance
Fit testing is often only treated as a regulatory requirement – something that must happen once a year to tick a box. Not only can this be dangerous, but as bodies naturally change and fluctuate, it can also have a psychological impact on wearers.
As the new BS 30417 guidance makes clear, fit is not a formality. It’s a foundational part of safety, comfort and confidence at work, and a critical factor in ensuring PPE performs as designed.
A well-fitting garment supports the wearer holistically. When fit is wrong, users compensate, adjust, or simply stop wearing the item as intended – as our latest report in the utilities sector found. That creates risk, but it also disrupts performance across the shift.
So, what is fit testing and why is it so much more than just compliance?
what fit testing actually is
Fit testing verifies that a piece of PPE forms the correct seal or sits correctly on an individual. It proves that the product can perform its purpose – not just that it passes technical standards. Typically, to fit test, the focus is the individual, their anatomy, and how the product interacts with their movement and environment.
BS 30417 reinforces that fit testing is part of a wider, person-centred approach. PPE should be suitable for the individual, not just technically compliant on paper.
comfort is a safety issue
Poor fit can lead to a wide range of problems, including pressure points, overheating, restricted movement, and compromised breathability. These are comfort issues, but they are also safety issues – discomfort causes distraction, fatigue, and an increased likelihood of readjusting PPE in unsafe situations.
For many users, particularly women, disabled workers, pregnant individuals, menopausal wearers, and those with varied body shapes, discomfort is the first sign that PPE has not been designed with them in mind. BS 30417 acknowledges this gap and challenges organisations to move beyond default sizing.
Good fit reduces physical strain and supports longer, safer wear. That benefits the wearer, but it also strengthens organisational safety culture.
fit and real-world performance
Protective garments only work when worn correctly, consistently and confidently. When users trust their PPE, they move more naturally and focus more clearly on the task at hand.
In contrast, a garment that rides up or feels too restrictive becomes a constant distraction. These micro-interruptions reduce productivity, slow decision-making, and create friction across the working day.
Fit testing builds trust by confirming that PPE will perform during real tasks, not just in controlled environments. It removes guesswork – and with it, a significant barrier to performance.
common misconceptions around fit testing
Many misconceptions persist across industries:
read the full BSI standard
what organisations can do differently
A modern approach to fit testing could include things such as:
engaging wearers early in selection and procurement
offering size-inclusive, gender-responsive, or adjustable options
ensuring a competent person oversees inclusive PPE processes
providing training so users know how to wear, adjust, and report issues
reviewing feedback and monitoring changes over time
selecting suppliers who understand ergonomic design, not just compliance
alsico and inclusive PPE
Alsico designs protective garments around the wearer – not the other way round. Our approach draws on innovative 3D design, ergonomic pattern cutting, extended size ranges, gender-responsive options, stretch fabrics, and continuous feedback loops with customers across high-risk sectors.
We are aligned with the principles of BS 30417, supporting organisations to provide PPE that fits more people the first time, and that adapts to real bodies, real tasks and real environments .
For teams seeking guidance on inclusive selection, wearer trials, fit testing, or improving existing PPE programmes, we serve as both a PPE manufacturer and a safety partner.
To learn more about improving fit, comfort and performance across your PPE programme, speak with our specialist team today.
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Protection is weaved into every part of alsico, we build it into everything we do and it drives our every decision. Our protective workwear range covers all high-safety sectors.
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We are always honored to be asked to provide workwear for our emergency services teams. We put our trust in them to help to look after us, and we do our very best in return, delivering performance when it matters.
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