Workwear Size Chart: XS–5XL Measurements in Detail

Workwear Sizing Standards

In workwear production, choosing sizes is a critical decision for staff comfort and brand consistency. The wrong size does not just make employees uncomfortable; it leads to T-shirts, polos, jackets and trousers losing their shape after washing, a mismatched look, and exchange and return costs. Mars Wear production is based on Turkish standard sizing (in line with Turkish Standards Institution TS 1080); 9 standard sizes are produced from XS to 5XL, and special sizes of 6XL+ on request.

For corporate companies, factories and production facilities, logistics firms, chain brands and healthcare chains, the right size breakdown is set by a measurement survey before ordering or by averaging past data. In this guide, we explain the standard measurement tables, the rules for choosing sizes, managing mixed orders and how special size needs are met.

Standard Size Chart (T-Shirts and Polos)

The measurements below apply to all work T-shirt, polo, mandarin-collar, V-neck and crew-neck models. Sweatshirt and fleece models include a 2–3 cm ease allowance.

Measuring points: Chest = measure flat from armpit to armpit and multiply by 2. Length = straight distance from the shoulder to the hem. Sleeve length = from the shoulder to the cuff.

Sweatshirt and Fleece Size Chart

Because sweatshirt, fleece and jacket models include an ease allowance, they are cut 2–3 cm wider than T-shirts. Someone who wears M in a T-shirt should also wear M in a sweatshirt (though it will feel roomier).

Work Trousers Size Chart

Work trouser sizes are set by the waist + length combination alongside upper-body measurements. For Mars Wear trousers, orders are taken with two parameters: waist + length.

The standard inside leg measurement for trousers is in the 80–86 cm range. A custom cut of +/- 4–6 cm is possible to suit the wearer's height.

Differences Between Men's and Women's Sizes

Mars Wear offers two sizing structures:

Unisex sizing: A single size run (XS–5XL) for all staff. Advantage: easy stock management, a price advantage. Disadvantage: it may come up one size large on female staff.

Women's sizing: A tapered waist, narrower shoulders and shorter sleeves. Produced in the XS–3XL range. Added on request, with a 5–8% price difference.

Most corporate companies prefer unisex sizing — especially for a uniform brand look and operational ease. Women's sizing is generally used in hotel chain receptions, retail stores, call centres and office towers.

Managing Mixed Orders

Different sizes can be distributed within a single order. An example of an average 100-piece mixed order:

• XS: 5 pieces (5%)
• S: 15 pieces (15%)
• M: 25 pieces (25%)
• L: 25 pieces (25%)
• XL: 15 pieces (15%)
• 2XL: 10 pieces (10%)
• 3XL: 5 pieces (5%)

This breakdown reflects statistics on the standard build of adult male staff in Türkiye. In mixed orders, no extra production charge is made for each size; a single price applies. If the size breakdown is not clear, the "standard breakdown" can be chosen, or a staff measurement survey can be done before ordering.

Special-Size Production (6XL and Above)

Sizes of 6XL, 7XL and larger are not on the standard production line, but are produced specially on request. Conditions:

• Minimum 10 pieces per size
• +5–7 working days on top of the standard production time
• A 15–25% price difference (due to less efficient fabric cutting)
• Individual measurements can be taken (a premium service, charged extra)

For very large sizes, pattern customisation continues linearly from the 5XL size; for extremely large sizes (8XL+), extra design work is needed to optimise the fabric structure and fit.

Size Selection Guide: How Do You Measure?

There are three main ways to get accurate measurements from staff:

1. From an existing T-shirt: Take the chest and length measurements, with a tape measure, of a T-shirt the person currently wears and feels is a "perfect fit". This is the quickest method.

2. Body measurement: Measure around the body from armpit to armpit without pulling tight — compare this measurement with the chest measurement in the table, allowing 4–6 cm of ease.

3. By sending samples: Mars Wear sends 3–4 standard sizes as samples by courier. Staff try them on and decide. Strongly recommended for a first order.

Fit Types

The same size looks very different in different cuts. Mars Wear production offers three fit options:

• Regular fit (standard): The classic corporate cut, chosen by 95% of customers. Stock available in all sizes.
• Slim fit: More tapered, a modern look. Preferred by tech companies and retail. +5% price.
• Loose fit: Wider, with high freedom of movement. For production line and workshop staff. +3% price.

Size Change After Washing

Depending on the fabric type, shrinkage after washing is a normal and expected process:

• 100% cotton piqué / single jersey: 3–5% shrinkage — the difference becomes clear after the first wash, then stays stable.
• 50% cotton + 50% polyester: 1–2% shrinkage — minimal loss of shape.
• 100% polyester dry-fit: No shrinkage — shape and size are kept.

To make up for shrinkage in 100% cotton products, we recommend ordering one size up — especially on first orders, even if staff feel it is "a bit big", a perfect fit is achieved after washing. For fabric choice and details, see the Fabric Guide page.

Size Breakdown Strategy for Multiple Locations

For chain brands, hospital groups and retail chains, the size breakdown by location is a strategic matter. Example scenarios:

• A retail chain with 50 stores: An average of 8–10 staff per store × a separate size breakdown. Packing by location is preferred.
• A group of 10 hospitals: Colour + size distinction by department (reception = white S–L, technical = blue L–XL, admin = navy S–2XL).
• A parcel company with 200 branches: A regional size trend analysis is done (e.g. XL average in the Black Sea region, L average in Marmara).

For this kind of structure, Mars Wear offers an annual framework agreement: the same batch colour all year + calibrated sizing + distribution by location + a seasonal changeover option.

If There Is a Size Error

Size errors can happen in two ways:

1. A wrong order from the customer's side: If the measurement given by a staff member is wrong, it does not count as a Mars Wear production fault. An exchange is possible, but an additional production charge applies (usually discounted).

2. A production fault: If a measurement deviation slips through Mars Wear quality control, a free exchange or return is made. The detection period is 30 days.

When placing a mixed order, we recommend ordering 5–10% extra stock of each size (e.g. 28 instead of 25 for M). This acts as a buffer for staff changes and size errors.

Frequently Asked Questions

What is the difference between Turkish standard sizing and European sizes?

Turkish sizes are produced to the TS 1080 standard; they are generally 1–2 cm smaller than EU sizes. A Turkish M (chest 100) = European S/M (chest 98–100). For international franchise and export orders, calibration to European measurements can be done.

Can sizes be estimated for T-shirts without taking measurements?

Yes, an average breakdown can be used: for 100 staff, a breakdown of XS:5, S:15, M:25, L:25, XL:15, 2XL:10, 3XL:5 gives 85% accuracy. However, a staff measurement survey is the safest method for a first order.

Is separate sizing for female staff essential?

It is not essential. Most corporate companies prefer unisex sizing — for operational ease + a uniform look. In sectors with high visual sensitivity, such as hotel reception, retail stores and call centres, women's sizing may be preferred.

Are special sizes of 6XL and above possible?

Yes. Special sizes are produced from a minimum of 10 pieces per size, with 5–7 working days' extra time and a 15–25% price difference. For very large sizes, individual measurements can be taken (a premium service, charged extra).

What can be done for staff with a different inside leg length?

The standard inside leg for trousers is 80–86 cm. For shorter (under 160 cm) or taller (over 190 cm) staff, a custom cut of +/- 4–6 cm is possible. It adds 10–15% to the cost, with a minimum of 5 pieces per measurement.

Is a T-shirt that shrinks after washing exchanged?

The fabric's natural shrinkage rate (3–5% for cotton) is not a production fault and is not covered by exchanges. That is why ordering one size up is recommended for 100% cotton orders. With polyester blend fabrics, shrinkage is minimal and the size choice matches the table exactly.

Can you switch between sizes?

An exchange of remaining stock is possible, but an extra charge applies. For mixed orders, the exact size breakdown should be approved before ordering; changing after production means running the production line again.

How is a size test done with samples?

For first orders, Mars Wear sends 3–4 standard sizes (S, M, L, XL) as samples by courier. Staff try them on and decide, then the final size breakdown is confirmed. The sample fee is credited once the total order is approved.

Conclusion: Choosing the Right Size

Three rules for choosing workwear sizes: 1) Get samples for a first order, 2) Choose one size up for 100% cotton, 3) Place a mixed order and add a 10% extra buffer. Mars Wear production offers XS–5XL as standard, 6XL+ as special sizes, and regular, slim and loose fit options.

For more information and to request samples, you can reach us through the quick quote form. You can browse all our models in the Work T-Shirts category, and see the fabric types that affect shrinkage in the Fabric Guide.