Big and tall high visibility clothing needs more than a bigger label. Large sizes (5XL to 8XL) and tall fits must be graded properly so chest, armholes, body length and sleeve length all grow in the right proportions, and the reflective tape must sit in the right place on the body. A surprising fact for many buyers: compliance with ANSI/ISEA 107 and EN ISO 20471 is assessed on the smallest size in a range, so adding big sizes is rarely a compliance problem — fit and tape placement are the real challenges.
Why Big and Tall Sizes Go Wrong
- Width without length: many ranges simply add chest width, leaving garments short in the body. Shirts ride up and expose the waist; tape bands sit too high.
- Tight armholes: armholes that do not grow with chest size restrict reaching.
- Tape not scaled: tape positioned for a medium can sit across the chest in the wrong place on a 6XL.
- Short sleeves on tall workers: sleeve bands end up at the forearm instead of the upper arm.
What Good Grading Looks Like
| Measurement | Big sizes (4XL–8XL) | Tall fit |
|---|---|---|
| Chest | Increases per size | Same as regular |
| Body length | Increases, so the hem covers the waist | Extra length added |
| Armhole | Grows with chest | Slightly deeper |
| Sleeve | Slight increase | Extra length added |
| Tape position | Repositioned to match body landmarks | Repositioned for longer torso |
Compliance and Large Sizes
Both main standards set minimum areas of background and reflective material for the class. Because larger garments carry more fabric and tape, the smallest size is the one that has to pass. That means:
- Extending a compliant range to 7XL or 8XL does not normally reduce compliance.
- The size range on the label should include the big sizes, and test reports should cover the range you buy.
- Tape still needs correct placement — the standards define where tape must go, not just how much.
From Our Factory Floor
Since 2004 we have made hi vis garments up to 8XL. What we do differently for big and tall:
- Separate grading rules for 4XL and above rather than continuing the small-size steps.
- Fit sessions with real large-size wearers when possible, because body proportions change at large sizes.
- Tall options (extra body and sleeve length) for shirts, jackets and coveralls.
- Size-specific tape positions marked on the patterns.
- Honest size charts with garment measurements, so buyers can match their crew rather than guessing from labels.
Ordering Tips
- Collect actual sizes from the crew list; construction and logistics crews often need more large sizes than standard curves assume.
- Ask for a fit sample in the largest size, not only in a medium.
- Specify tall options separately in the order.
- Check that outerwear fits over layers in the big sizes too.
FAQ
Do you make hi vis clothing in 7XL and 8XL?
Yes, across vests, shirts, hoodies, jackets and coveralls, depending on style.
Are big sizes more expensive?
They use more fabric and tape, so large sizes often cost more per piece. Your quote will show this.
Do big sizes need separate certification?
The certification covers a size range. Make sure the range on the label includes the sizes you order.
Request a Quote
Send us your size breakdown including big and tall sizes, the styles, class and logo. We will confirm size charts and send a large-size fit sample. Contact our team.
This guide is general information from a hi vis clothing manufacturer. Always confirm the standard, class and site rules that apply to your work; the published standards are the final reference.
