The Short Answer: As of January 13, 2025, OSHA requires construction employers to ensure all personal protective equipment properly fits each worker under the updated construction standard 29 C.F.R. § 1926.95(c). This final rule aligns construction with general industry regulations, making proper fit an explicit requirement, not a suggestion. Employer responsibilities now include confirming that protective equipment meets hazard standards and fits correctly to deliver adequate protection and reduce risk.
For years, safety programs emphasized “meeting the hazard”. This included selecting the right PPE types for the job, such as hard hats, gloves, safety harnesses, and safety glasses. However, one critical factor was consistently overlooked: proper fit.
OSHA issued an updated rule in January 2025, placing fit requirements at the center of occupational safety. Ill-fitting gear isn’t just uncomfortable. It can’t provide the protection you rely on and can even create new hazards. Oversized gloves can catch on moving equipment, poorly fitted safety glasses can reduce visibility, and a loose harness can shift or fail under load when it matters most.
The updated OSHA rule makes it clear: providing PPE is not enough, it must also properly fit each worker.
At Malta Dynamics, we build gear for how construction workers actually operate, designed to move, protect, and perform in real jobsite conditions where worker safety depends on equipment that works.
Understanding the New Proper-Fit PPE Rule
What Changed? The New Requirements Under 29 C.F.R. § 1926.95(c)
OSHA revised the construction standard to make one point unmistakable: protective equipment must properly fit each construction worker. The new rule requires employers to provide PPE that is both safely designed for workplace hazards and correctly fitted to the individual wearing it.
This update aligns the construction industry with general industry and shipyard PPE standards, closing a long-standing safety gap. Effective January 13, 2025, it marks the first time OSHA has made proper fit an explicit requirement in construction safety regulations.
OSHA's Reasoning
Poorly sized or adjusted equipment reduces protection, creates new hazards, and can lead workers to handle their gear unsafely. Loose clothing can catch on machinery, while tight gear restricts movement and causes distraction. Over time, discomfort often leads workers to modify their PPE, eliminating its protective value entirely.
While OSHA previously cited improper fit under broader provisions, the new requirement embeds fit directly into the PPE standard. Construction employers must now demonstrate that protective equipment fits correctly, not simply that it was issued.
Why Proper Fit Cannot Be Ignored
Fit Failures Create Real Hazards
Personal protective equipment that doesn't fit can be as dangerous as working without protection.
Common examples across the construction industry include:
- A hard hat that shifts during movement fails to absorb impact where needed.
- Oversized gloves catch on tools, controls, or rotating parts.
- A poorly fitted harness allows excessive movement or slippage during arrest.
One Size Fails Most Workers
Larger workers, smaller construction workers, and female workers often fall outside standard sizing ranges.When gear doesn’t fit properly, workers may tighten buckles too much, alter straps, or wear equipment incorrectly. These adjustments reduce protection and increase the risk of injury.
Comfort Drives Compliance
When protective clothing pinches, restricts motion, or adds unnecessary pressure, workers loosen or remove the gear to relieve discomfort. In real conditions where weather, repetitive motion, and tool handling already add stress, a poor fit compounds risk and reduces the effectiveness of safety policies.
The Cost of Ignoring Fit
Ignoring fit doesn't just risk OSHA citations. It leads to preventable injuries, lost time, damaged morale, and higher costs: outcomes no safety program can afford.
Building a Proper-Fit PPE Compliance Plan
1. Start with an Inventory Audit
- Review every PPE type in use: safety harnesses, gloves, hard hats, safety glasses, hearing protection, protective footwear, and protective clothing.
- Compare available sizes to body types across your crew to identify gaps where current inventory doesn't provide adequate protection.
2. Fit Assessment Process
- Take accurate measurements: chest, waist, inseam, head circumference.
- Test gear in the field under actual working conditions, not only during static fittings.
3. Source Inclusive Sizing for All Workers
- Purchase protective equipment in multiple sizes and adjustable models.
- Select suppliers offering extended sizing and product lines designed for female workers and individuals with builds outside standard ranges.
4. Update Policies and Documentation
- Add proper fit as a documented requirement in your written safety policies.
- Record fit checks, replacement schedules, and worker feedback to maintain compliance records that demonstrate employer responsibilities are met.
5. Improve Training and Communication
- Train workers to recognize when personal protective equipment doesn't fit properly.
- Build open communication so crews hold each other accountable and report issues without delay.
6. Regular PPE Inspection and Replacement
- Include fit evaluation in every PPE inspection.
- Replace any item stretched, worn, torn, or unable to maintain proper adjustment, even if it otherwise appears serviceable.
7. Track Results and Improvements
- Track incidents and near-misses tied to poor fit.
- Use insights to refine procurement, update safety standards, and strengthen training programs.
Why a Plan Matters
With OSHA's new requirement in effect, employers must document that protective equipment fits crews correctly and performs as intended. Each step should confirm that gear delivers appropriate protection, remains compliant, and supports workers under real conditions.
Partnering with trusted providers like Malta Dynamics ensures access to consistent sizing options, reliable support, and streamlined compliance on the jobsite.
Choosing PPE That Fits Right: Key Attributes
Adjustability and Variability
Protective equipment with multiple adjustment points (straps, buckles, sliders) allows workers to fine-tune fit throughout the shift. Adjustable gear also reduces pressure points and maintains appropriate protection as tasks and positions change.
Design for Fit
Choose products engineered with body shape and proportion in mind. Gender-specific and extended-size options ensure a secure fit without forcing workers into unsafe compromises that undermine the safe design of the equipment.
Material Performance Under Load
Weight, heat, moisture, and motion affect how protective equipment fits during real use. Select materials that hold form under stress and resist stretching or slipping when exposed to dirt, sweat, or repetitive movement common in hazardous conditions.
Compatibility with Other Gear
Each piece must function as part of a complete system. Safety harnesses, lanyards, respirators, and safety glasses should integrate without interference, discomfort, or gaps in protection.
Training, Inspection, and Accountability
Training for Workers
- Teach workers to identify correct fit by checking comfort, coverage, and mobility.
- Demonstrate how to adjust straps, closures, and harness points for full range of motion.
- Emphasize signs of poor fit: pinching, slipping, restricted movement, or visible gaps.
Daily Inspections
- Include proper-fit checks in every PPE inspection routine.
- Supervisors and workers should verify all gear remains correctly adjusted before each shift.
Encourage Reporting
- Create a simple process for workers to report fit issues without penalty or delay.
- Foster open communication so teams keep each other accountable and problems are corrected quickly.
Supervisor Responsibility
- Supervisors document feedback, fit adjustments, and replacements.
- Record incidents, near-misses, or concerns related to PPE fit to support compliance records and refine training.
Embedding Proper Fit into Safety Culture
Make Fit Part of Daily Conversations
Include fit reminders in toolbox talks and pre-shift briefings. Regular discussion keeps awareness high and prevents small issues from escalating into potential hazards.
Use Visual Cues
Post clear reminders near gear stations: "Check your fit before you gear up." Visual prompts reinforce habits even on busy days when crews are under pressure.
Reward Reporting and Lead by Example
Recognize workers who identify fit problems early. Supervisors should model correct fit and adjustment procedures, reinforcing that proper sizing isn't optional but a safety requirement rooted in employer responsibilities and worker safety.
Over time, consistent communication builds trust and accountability. Crews equipped with properly fitting personal protective equipment work with greater confidence and stay protected.
Fit Is Safety, Not Just Compliance
The updated OSHA rule makes one thing clear: protective equipment only protects when it fits. Compliance now includes ensuring every construction worker can wear gear safely and comfortably, not just issuing it.
As of January 13, 2025, construction employers must verify that personal protective equipment is both task-appropriate and properly fitted to each individual. Workplace safety goes beyond meeting the new requirement. It's about giving every worker the necessary protection to perform with confidence and return home safely each day.
At Malta Dynamics, we engineer personal protective equipment that adapts to real people and real work. Our safety harnesses, gloves, and hard hats are built for every body type and tested in the field to deliver dependable protection under hazardous conditions.
Explore Malta Dynamics' full line of inclusive PPE built for lasting comfort, reliable performance, and total compliance with consensus standards.
