Size-Inclusive Workwear: The 2026 U.S. Catalog Availability Report

A uniform can be offered in an extended size without every color or companion cut being offered in that size. This 2026 report examines that distinction using three current U.S. wholesale apparel catalogs and a complete color-level snapshot of one T-shirt style.

The catalog audit includes 327 adult style entries across tees, polos and outerwear. Of the 310 non-tall entries, 234 advertised a maximum of at least 4XL, while 46 advertised at least 5XL. A separate analysis of Next Level Apparel's 3600 T-shirt found listed variants through 3XL in all 46 captured colors, but 5XL and 6XL in eight colors. These are findings about the selected catalog documents and captured product listings. They do not establish warehouse stock, fit on a person or coverage of the U.S. workforce. 1 2 3 4 5

For buyers, the implication is practical: define the required combination of garment, cut, color and size before committing to a uniform program. Then confirm the exact combinations, measurements, quantities and delivery terms. A headline maximum is a useful starting point, but it cannot complete those checks.

Executive summary

This study has two components. The first inventories the complete adult entries in SanMar's 2026 Tee, Polo and Outerwear Navigators. The second examines all color-specific product pages listed on the official Next Level 3600 page at capture. The two components answer different questions and use separate denominators.

Finding	Observed result	What the result measures
Adult catalog entries	327	Entries in three selected distributor documents
Non-tall entries advertising at least 4XL	234 of 310; 75.5%	Published maximum size label
Non-tall entries advertising at least 5XL	46 of 310; 14.8%	Published maximum size label
Explicitly women's entries advertising at least 5XL	4 of 110; 3.6%	Catalog labels within that cut group
Explicitly tall entries	17	Separate tall-style entries; excluded from non-tall thresholds
Next Level 3600 colors listing 4XL	35 of 46; 76.1%	Captured color-specific product variants
Next Level 3600 colors listing 5XL and 6XL	8 of 46; 17.4%	Captured color-specific product variants

Source: Arklavo calculations from the frozen September 14 captures. Percentages are rounded to one decimal place; downloadable results retain two decimal places. 4 5

Five conclusions follow:

1. The threshold matters. 3XL, 4XL and 5XL produce substantially different catalog counts. “Extended sizing” needs a stated definition in any purchasing brief.
2. Cuts need separate checks. The selected documents contain both matching published ranges and narrower companion ranges. Neither pattern should be assumed across a brand.
3. Color breadth is a separate variable. A published color count does not show which colors reach the advertised maximum.
4. Tall is a distinct range. A tall label should remain distinct from a regular label in both analysis and ordering.
5. Listing coverage is only the first procurement check. Dimensions, wearer preference, functional suitability, current quantities and replenishment still require confirmation.

The report is fully accessible without registration. Its data tables and calculation files allow readers to inspect the source of each reported count. The methodology section explains the sample boundaries and the distinction between a dated catalog observation and an operational availability claim.

1. The purchasing question: can the whole program be specified?

A company choosing a uniform is often selecting several things at once: a garment category, a brand or collection, one or more colors, different cuts, a decoration method and a range of sizes. It may also need different garments for indoor work, outdoor conditions or particular roles. Each choice changes the set of combinations that needs to be checked.

A product page can answer “Does this style reach 6XL?” while leaving “Does the chosen color reach 6XL?” unresolved. A catalog family can contain a standard and a women's garment while listing different maximum labels. Even matching maximum labels and color counts do not establish that the same named colors are offered in both cuts.

The question for procurement is therefore more precise than whether a supplier offers plus-size workwear. It is whether the particular proposed program can be supplied across its declared requirements. That question has at least four levels:

This study measures the first level across the selected catalogs and the second level for the 3600 case study. It does not substitute for the third or fourth. That boundary is useful: it prevents a catalog comparison from being presented as a fit study or a forecast of supply performance.

The word “inclusive” also deserves a clear boundary. Size labels are one observable feature of a uniform range. They do not capture mobility, dressing assistance, sensory preferences, garment closures, religious requirements or whether a person wants a particular cut. NIOSH's overview of anthropometry describes physical size, form and functional capacity as distinct considerations in the relationship between people and their work environment. Its discussion concerns work and protective equipment more broadly; it does not validate the garments in this report. 6

Our contribution is a reproducible description of catalog size coverage and one color-specific listing matrix. It gives a buyer more precise questions to ask without claiming that label counts measure inclusion in full.

2. What the 2026 audit covers

A complete inventory within three selected documents

SanMar's product-navigation page linked current 2026 navigators for tees, polos and outerwear when the documents were captured on September 14, 2026. We selected these three documents because the categories are relevant to a business apparel program and because their entries provide comparable style, size and color-count information. All eligible adult entries in each document were retained. The selection was not expanded or reduced according to the resulting maximum sizes. 1 2 3 7

The adult total contains 200 standard, adult, unisex or otherwise unmarked adult-context entries, 110 explicitly women's entries, and 17 explicitly tall entries. We do not relabel every unmarked entry as men's. That would add a gender classification that the catalog row itself did not provide. 4

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The catalog inventory and analysis frames: equivalent figure data

measure	count	source	scope	observed_date
All product entries	369	SanMar 2026 Tee, Polo and Outerwear Navigators; Arklavo coding	Selected document inventory	2026-09-14
Youth exclusions	42	SanMar 2026 Tee, Polo and Outerwear Navigators; Arklavo coding	Selected document inventory	2026-09-14
Adult retained	327	SanMar 2026 Tee, Polo and Outerwear Navigators; Arklavo coding	Selected document inventory	2026-09-14
Standard/adult/unisex/other	200	SanMar 2026 Tee, Polo and Outerwear Navigators; Arklavo coding	Selected document inventory	2026-09-14
Explicitly women	110	SanMar 2026 Tee, Polo and Outerwear Navigators; Arklavo coding	Selected document inventory	2026-09-14
Tall	17	SanMar 2026 Tee, Polo and Outerwear Navigators; Arklavo coding	Selected document inventory	2026-09-14
Non-tall threshold denominator	310	SanMar 2026 Tee, Polo and Outerwear Navigators; Arklavo coding	Selected document inventory	2026-09-14
Adult tees	130	SanMar 2026 Tee, Polo and Outerwear Navigators; Arklavo coding	Selected document inventory	2026-09-14
Adult polos	100	SanMar 2026 Tee, Polo and Outerwear Navigators; Arklavo coding	Selected document inventory	2026-09-14
Adult outerwear	97	SanMar 2026 Tee, Polo and Outerwear Navigators; Arklavo coding	Selected document inventory	2026-09-14

Long-sleeve tees remain in the tee frame, and vests remain in outerwear. They appear in the selected documents and can form part of a program. This is therefore a comparison of the navigator collections, not a narrowly controlled comparison of identical short-sleeve garments.

Every retained adult entry had a parseable published size range and color count. Missingness was nevertheless part of the protocol: an absent or unreadable range would have stayed in the inventory and been excluded only from calculations requiring that field. No missing adult ranges or color counts occurred in these captured documents. One photograph callout repeated three style codes already listed elsewhere; it was logged as a non-product callout rather than counted as three additional products. 4

A separate color-specific case study

The Next Level 3600 page exposed 46 distinct color-page identifiers, called product handles, in the first production capture. Each identifier points to a color-specific product record. We froze the complete list, retrieved every associated public record, and checked its listed size options against the individual variants. All 46 captures succeeded, providing 373 distinct listed size–color variants. 5

The 3600 was chosen during feasibility work because its published style-wide range and accessible color records allowed the central question to be tested. It is an illustrative, purposively chosen case. It is not a random sample of T-shirts, a sample of all Next Level styles or evidence of how often color restrictions occur across the market.

The 2026 designation refers to this report edition, the 2026 catalogs and the September 14, 2026 observation date. It does not mean that every supporting source was published in 2026. A currently linked Next Level sell sheet bears a 2025 copyright, and NIOSH's conceptual overview is dated 2024. Those dates remain explicit. 6 8

3. Published coverage changes sharply between 4XL and 5XL

Of the 310 parseable non-tall catalog entries, 285 advertised a maximum of at least 3XL, 234 at least 4XL, and 46 at least 5XL. The corresponding shares were 91.9%, 75.5% and 14.8%. Each calculation uses the same denominator and measures the advertised maximum label. 4

This is why a question phrased only as “Do you offer extended sizes?” is difficult to evaluate. Two suppliers could both answer yes while referring to different labels, cuts or colors. A purchasing specification should state the labels and the relevant product dimensions, rather than rely on the phrase alone.

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Published coverage depends on the size threshold: equivalent figure data

category	cut_group	threshold	numerator	denominator	percent	source	scope	observed_date
tee	all_non_tall	3XL	118	125	94.4	SanMar 2026 navigators; Arklavo calculations	Non-tall entries in selected category document	2026-09-14
tee	all_non_tall	4XL	87	125	69.6	SanMar 2026 navigators; Arklavo calculations	Non-tall entries in selected category document	2026-09-14
tee	all_non_tall	5XL	23	125	18.4	SanMar 2026 navigators; Arklavo calculations	Non-tall entries in selected category document	2026-09-14
polo	all_non_tall	3XL	80	91	87.91	SanMar 2026 navigators; Arklavo calculations	Non-tall entries in selected category document	2026-09-14
polo	all_non_tall	4XL	71	91	78.02	SanMar 2026 navigators; Arklavo calculations	Non-tall entries in selected category document	2026-09-14
polo	all_non_tall	5XL	17	91	18.68	SanMar 2026 navigators; Arklavo calculations	Non-tall entries in selected category document	2026-09-14
outerwear	all_non_tall	3XL	87	94	92.55	SanMar 2026 navigators; Arklavo calculations	Non-tall entries in selected category document	2026-09-14
outerwear	all_non_tall	4XL	76	94	80.85	SanMar 2026 navigators; Arklavo calculations	Non-tall entries in selected category document	2026-09-14
outerwear	all_non_tall	5XL	6	94	6.38	SanMar 2026 navigators; Arklavo calculations	Non-tall entries in selected category document	2026-09-14

The calculation does not require us to decide whether a label should count as plus-size in every context. We set explicit thresholds and show the results at each one. The reader can select the threshold relevant to the program and inspect the individual entries behind it.

Category differences

The three document frames showed different patterns. Tees and polos had similar proportions reaching at least 5XL, while the outerwear frame had a lower proportion. At the 4XL threshold, however, outerwear had the highest share of the three frames. 4

The category result is descriptive. These are curated collections with different brand mixes, cuts and intended uses. It would be inappropriate to conclude that one type of garment inherently supports fewer body types or that its production is less inclusive. We did not hold construction, price, fabric or target customer constant.

For a buyer building a multi-garment program, the result supports a sequencing recommendation: check the most constrained required garment early. A tee that satisfies the brief does not establish that the selected jacket will do so. Equally, an outerwear list with broad 4XL coverage should not be dismissed simply because fewer entries reach 5XL. The relevant constraint is the actual requirement, not a universal ranking of categories.

Why the denominator is 310 in this section

The headline adult inventory is 327, but 17 entries use explicitly tall ranges. Combining regular and tall labels into one ordered sequence would erase a distinction present in the sources. The threshold denominator therefore contains all 310 non-tall adult entries; the 17 tall entries remain in the inventory and are described in Section 5.

No weighting is applied for sales, number of employees, brand prominence or number of colors. Each catalog entry has one observation. A style with many colors does not contribute more weight to this particular calculation, and the percentages should not be interpreted as shares of purchases or production.

4. Companion cuts require their own specification

The explicitly women's frame contained 110 entries. Of these, 86 advertised at least 3XL, 78 at least 4XL, and four at least 5XL. In the 200-entry standard/adult/unisex/other group, the corresponding counts were 199, 156 and 42. 4

The difference at 5XL is a difference in published size labels across these catalog groups. It is not a measure of the proportion of men or women who could obtain suitable clothing. A body-coverage conclusion would require measurements, information about the relevant population and an appropriate assessment of garment shape and fit.

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Maximum size labels by catalog cut group: equivalent figure data

cut_group	maximum_label	count	denominator	percent	source	scope	observed_date
standard_other	2XL	1	200	0.5	SanMar 2026 navigators; Arklavo calculations	Published maximum labels, not wearer measurements	2026-09-14
standard_other	3XL	43	200	21.5	SanMar 2026 navigators; Arklavo calculations	Published maximum labels, not wearer measurements	2026-09-14
standard_other	4XL	114	200	57.0	SanMar 2026 navigators; Arklavo calculations	Published maximum labels, not wearer measurements	2026-09-14
standard_other	5XL	13	200	6.5	SanMar 2026 navigators; Arklavo calculations	Published maximum labels, not wearer measurements	2026-09-14
standard_other	6XL	29	200	14.5	SanMar 2026 navigators; Arklavo calculations	Published maximum labels, not wearer measurements	2026-09-14
women	2XL	24	110	21.82	SanMar 2026 navigators; Arklavo calculations	Published maximum labels, not wearer measurements	2026-09-14
women	3XL	8	110	7.27	SanMar 2026 navigators; Arklavo calculations	Published maximum labels, not wearer measurements	2026-09-14
women	4XL	74	110	67.27	SanMar 2026 navigators; Arklavo calculations	Published maximum labels, not wearer measurements	2026-09-14
women	5XL	0	110	0.0	SanMar 2026 navigators; Arklavo calculations	Published maximum labels, not wearer measurements	2026-09-14
women	6XL	4	110	3.64	SanMar 2026 navigators; Arklavo calculations	Published maximum labels, not wearer measurements	2026-09-14

There is also a difference in composition. The standard/other group includes long-sleeve entries and unisex products as well as unmarked standard cuts. The women's group is defined by explicit wording. Those groups are transparent and reproducible, but they are not two experimentally matched collections.

Examples show both matching and different ranges

Within the selected catalogs, some named families published matching size ranges and some did not. These examples demonstrate why family-level checking is more useful than assuming a single rule for a whole brand. 1 2 3

These are documentary comparisons, not purchasing recommendations or judgments about the garments. Companion products can differ in construction and proportions. A shared family name is evidence of catalog grouping, not proof that the two garments are otherwise identical.

The four women's entries reaching the 5XL threshold were all polos, and each advertised a maximum of 6XL: LK240, LK200, L100 and L500. The captured tee and outerwear frames contained no explicitly women's entry with a published maximum of at least 5XL. This finding is confined to those two documents; it does not establish that such garments are unavailable from the distributor's full inventory or from other suppliers. 2 4

Equal color counts do not establish matching colors

The median published color count was 10 in the standard/other group and 6.5 in the women's group. Across categories, however, the pattern varied. The polo medians were both eight and the outerwear medians were both four. In tees, the medians were 19.5 and 12, respectively. 4

These medians summarize document entries. They do not measure matching colors across cuts. Two garments could each list eight colors and share all eight, some of them or none. The catalogs' counts alone do not resolve that question. Publishing a “matching-color availability” percentage from these counts would therefore exceed the evidence.

5. Tall ranges form a separate purchasing track

The selected documents contained 17 tall entries: five in tees, nine in polos and three in outerwear. Sixteen advertised LT–4XLT and one, Gildan 2000T, advertised LT–3XLT. The median advertised color count across the tall entries was five. 4

The purpose of separating these entries is to preserve the catalog's distinction. A 4XLT label is not treated as another way to write 4XL. This report has not measured how much any particular tall garment differs from its regular companion, and it does not translate either label into a body dimension.

A program requiring tall options should check the exact tall style code, range, color and measurements. The source entries make clear that a named family may have different color counts for standard, women's and tall cuts. For example, the Silk Touch polo entries advertise 34 colors for K500, 34 for L500 and 12 for TLK500. The Core Soft Shell entries advertise 11 for J317, 10 for L317 and three for TLJ317. Those are published counts, not confirmed intersections. 2 3

The relatively small tall frame should not be interpreted as the total choice in the U.S. market. It is the number of explicitly tall entries included in these curated documents. Additional styles, suppliers or made-to-order routes may exist outside the frame; they were not inventoried here.

6. A style-wide 6XL range becomes an eight-color listing set

The Next Level 3600 product page gives a generic size range of XS–6XL. Its 2026 catalog also distinguishes the base range from selected colors offered in larger labels. We examined the actual listed variants for every color handle shown on the captured product page. 5 9

All 46 colors listed XS, S, M, L, XL, 2XL and 3XL. At 4XL, the count was 35 colors. At 5XL and 6XL, it was eight colors. All eight of those colors listed the complete sequence from XS through 6XL. No color capture was missing. 5

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Next Level 3600: color breadth at each listed size: equivalent figure data

size_label	colors_with_listed_size	successfully_captured_colors	frame_colors	percent	source	scope	observed_date
XS	46	46	46	100.0	Next Level Apparel 3600 public color product representations	One style; all handles in the captured manufacturer frame; listed variants only	2026-09-14
S	46	46	46	100.0	Next Level Apparel 3600 public color product representations	One style; all handles in the captured manufacturer frame; listed variants only	2026-09-14
M	46	46	46	100.0	Next Level Apparel 3600 public color product representations	One style; all handles in the captured manufacturer frame; listed variants only	2026-09-14
L	46	46	46	100.0	Next Level Apparel 3600 public color product representations	One style; all handles in the captured manufacturer frame; listed variants only	2026-09-14
XL	46	46	46	100.0	Next Level Apparel 3600 public color product representations	One style; all handles in the captured manufacturer frame; listed variants only	2026-09-14
2XL	46	46	46	100.0	Next Level Apparel 3600 public color product representations	One style; all handles in the captured manufacturer frame; listed variants only	2026-09-14
3XL	46	46	46	100.0	Next Level Apparel 3600 public color product representations	One style; all handles in the captured manufacturer frame; listed variants only	2026-09-14
4XL	35	46	46	76.09	Next Level Apparel 3600 public color product representations	One style; all handles in the captured manufacturer frame; listed variants only	2026-09-14
5XL	8	46	46	17.39	Next Level Apparel 3600 public color product representations	One style; all handles in the captured manufacturer frame; listed variants only	2026-09-14
6XL	8	46	46	17.39	Next Level Apparel 3600 public color product representations	One style; all handles in the captured manufacturer frame; listed variants only	2026-09-14

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The complete Next Level 3600 color-size listing matrix: equivalent figure data

color	handle	XS	S	M	L	XL	2XL	3XL	4XL	5XL	6XL	listed_size_count	maximum_label	legend	source	scope	observed_date
Antique Gold	unisex-cotton-t-shirt-antique-gold	1	1	1	1	1	1	1	1	0	0	8	4XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Banana Cream	unisex-cotton-t-shirt-banana-cream	1	1	1	1	1	1	1	1	0	0	8	4XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Black	unisex-cotton-t-shirt-black	1	1	1	1	1	1	1	1	1	1	10	6XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Blue Jean	unisex-cotton-t-shirt-blue-jean	1	1	1	1	1	1	1	0	0	0	7	3XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Bone	cotton-t-shirt-bone	1	1	1	1	1	1	1	0	0	0	7	3XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Cardinal	unisex-cotton-t-shirt-cardinal	1	1	1	1	1	1	1	1	0	0	8	4XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Classic Orange	unisex-cotton-t-shirt-classic-orange	1	1	1	1	1	1	1	0	0	0	7	3XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Clay	cotton-t-shirt-clay	1	1	1	1	1	1	1	0	0	0	7	3XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Cool Blue	unisex-cotton-t-shirt-cool-blue	1	1	1	1	1	1	1	1	0	0	8	4XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Cream	unisex-cotton-t-shirt-cream	1	1	1	1	1	1	1	1	0	0	8	4XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Dark Chocolate	unisex-cotton-t-shirt-dark-chocolate	1	1	1	1	1	1	1	0	0	0	7	3XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Desert Pink	unisex-cotton-t-shirt-desert-pink	1	1	1	1	1	1	1	1	0	0	8	4XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Forest Green	unisex-cotton-t-shirt-forest-green	1	1	1	1	1	1	1	1	0	0	8	4XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Gold	unisex-cotton-t-shirt-gold	1	1	1	1	1	1	1	1	0	0	8	4XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Graphite Black	unisex-cotton-t-shirt-graphite-black	1	1	1	1	1	1	1	1	0	0	8	4XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Heather Gray	unisex-cotton-t-shirt-heather-gray	1	1	1	1	1	1	1	1	1	1	10	6XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Heavy Metal	unisex-cotton-t-shirt-heavy-metal	1	1	1	1	1	1	1	1	1	1	10	6XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Hot Pink	cotton-t-shirt-hot-pink	1	1	1	1	1	1	1	1	1	1	10	6XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Indigo	unisex-cotton-t-shirt-indigo	1	1	1	1	1	1	1	1	0	0	8	4XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Kelly Green	unisex-cotton-t-shirt-kelly-green	1	1	1	1	1	1	1	1	0	0	8	4XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Light Blue	unisex-cotton-t-shirt-light-blue	1	1	1	1	1	1	1	1	0	0	8	4XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Light Gray	unisex-cotton-t-shirt-light-gray	1	1	1	1	1	1	1	1	0	0	8	4XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Light Olive	unisex-cotton-t-shirt-light-olive	1	1	1	1	1	1	1	1	0	0	8	4XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Light Pink	unisex-cotton-t-shirt-light-pink	1	1	1	1	1	1	1	1	0	0	8	4XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Maroon	unisex-cotton-t-shirt-maroon	1	1	1	1	1	1	1	1	0	0	8	4XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Mauve	unisex-cotton-t-shirt-mauve	1	1	1	1	1	1	1	1	0	0	8	4XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Midnight Navy	unisex-cotton-t-shirt-midnight-navy	1	1	1	1	1	1	1	1	1	1	10	6XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Military Green	unisex-cotton-t-shirt-military-green	1	1	1	1	1	1	1	1	0	0	8	4XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Natural	unisex-cotton-t-shirt-natural	1	1	1	1	1	1	1	1	0	0	8	4XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Oatmeal	unisex-cotton-t-shirt-oatmeal	1	1	1	1	1	1	1	0	0	0	7	3XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Oxblood	unisex-cotton-t-shirt-oxblood	1	1	1	1	1	1	1	1	0	0	8	4XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Peri Blue	unisex-cotton-t-shirt-peri-blue	1	1	1	1	1	1	1	0	0	0	7	3XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Purple Rush	unisex-cotton-t-shirt-purple-rush	1	1	1	1	1	1	1	1	0	0	8	4XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Red	unisex-cotton-t-shirt-red	1	1	1	1	1	1	1	1	1	1	10	6XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Royal	unisex-cotton-t-shirt-royal	1	1	1	1	1	1	1	1	1	1	10	6XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Royal Pine	unisex-cotton-t-shirt-royal-pine	1	1	1	1	1	1	1	1	0	0	8	4XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Sand	unisex-cotton-t-shirt-sand	1	1	1	1	1	1	1	0	0	0	7	3XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Shiitake	cotton-t-shirt-shiitake	1	1	1	1	1	1	1	1	0	0	8	4XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Stonewash Denim	unisex-cotton-t-shirt-stonewash-denim	1	1	1	1	1	1	1	1	0	0	8	4XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Tahiti Blue	unisex-cotton-t-shirt-tahiti-blue	1	1	1	1	1	1	1	1	0	0	8	4XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Tan	unisex-cotton-t-shirt-tan	1	1	1	1	1	1	1	0	0	0	7	3XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Teal	unisex-cotton-t-shirt-teal	1	1	1	1	1	1	1	0	0	0	7	3XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Turquoise	unisex-cotton-t-shirt-turquoise	1	1	1	1	1	1	1	1	0	0	8	4XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Warm Gray	unisex-cotton-t-shirt-warm-gray	1	1	1	1	1	1	1	1	0	0	8	4XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
Watermelon	unisex-cotton-t-shirt-watermelon	1	1	1	1	1	1	1	0	0	0	7	3XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14
White	unisex-cotton-t-shirt-white	1	1	1	1	1	1	1	1	1	1	10	6XL	1=listed;0=not listed in captured representation	Official Next Level Apparel 3600 color product records	Complete captured frame of one selected style; no stock interpretation	2026-09-14

The eight colors with all ten size labels were Black, Heather Gray, Heavy Metal, Hot Pink, Midnight Navy, Red, Royal and White. This list describes the captured product representation on September 14, 2026. It is not a promise of immediate supply or a statement that any particular quantity can be ordered. 5

The complete color groups

The downloadable matrix contains every observed color and size label. For readers evaluating a proposed palette, the same observations can be summarized by the maximum listed size:

Source: complete captured color frame and individual product variant records. The 6XL group also contains 5XL; no color's maximum in this capture was 5XL. 5

The matrix contains 373 listed variants out of 460 possible cells in a ten-label-by-46-color grid. The remaining 87 cells have no corresponding listed variant in the captured representation. This is a count of a defined grid, not a stockout measure, an industry-wide shortage rate or a claim that the missing combinations have never been produced. 5

Why listing and stock were kept separate

A product representation can retain a listed variant even when its public availability flag is false. Removing such variants would turn a catalog study into a volatile availability snapshot with a different meaning. We therefore counted every listed variant, checked its style and size identifiers, and excluded public stock flags from the published analysis.

This choice is deliberate. It allows the matrix to answer whether the exact size–color combination is represented in the captured catalog record. It cannot answer how many units are in a warehouse, whether a distributor has its own stock, what lead time applies or whether an account can place a particular order.

For the same reason, the report does not publish a size-surcharge chart. Public representations can contain prices without establishing the relevant account, quantity, decoration, shipping or commercial terms. A meaningful surcharge comparison requires a matched quotation basis that this study did not collect.

Do not combine different catalog representations silently

The SanMar Tee Navigator lists 45 colors for NL3600, whereas the captured manufacturer product page exposed 46 color handles. These are different catalog representations, not interchangeable denominators. We use the navigator count for the distributor document audit and the full manufacturer handle frame for the variant study. 1 5

The currently linked 3600 sell sheet also differs from the captured variant records in specific details. Its 2025-copyright artwork marks Light Gray with 4XL–6XL, while the captured Light Gray product record lists through 4XL. The study cannot establish the reason for that difference. We preserve both sources and use the captured variant record for the defined listing matrix. A buyer needing that combination should request explicit confirmation. 5 8

This is not evidence of an inaccurate order, withdrawn production or supplier misconduct. It is an example of why a dated, source-specific statement is more useful than merging multiple documents into an apparently timeless product fact.

7. Turn the evidence into a uniform-program decision

The study supports a sequence of checks. The following is a proposed procurement method derived from the distinction between catalog entries and exact combinations. It has not been validated as a cost-saving intervention or a measure of wearer satisfaction.

Step 1: write the requirement before choosing the visual identity

Specify the garment categories, the cuts people may choose, the required size labels and the measurements that need checking. Include any role-specific requirements. Avoid assuming that a unisex entry satisfies every person's preference or that everyone with the same usual label will choose the same garment.

Enlarge figure ↗SVGPNGCSV

Read the data behind this figure (4 rows)

Four evidence checks before approving a uniform program: equivalent figure data

step	stage	question	evidence_needed	status	basis	sample_denominator	observed_date
1	Catalog range	Does the exact style advertise the required size labels?	Current style-specific catalog entry.	Proposed workflow, not tested for outcomes	Arklavo synthesis of catalog and variant study; measurement guidance	Not applicable to proposed workflow	2026-09-14
2	Exact variants	Do the required cut, color and size combinations appear?	Variant records or written supplier confirmation.	Proposed workflow, not tested for outcomes	Arklavo synthesis of catalog and variant study; measurement guidance	Not applicable to proposed workflow	2026-09-14
3	Wearer suitability	Do dimensions, shape and function meet the requirement?	Product measurements, samples and wearer assessment.	Proposed workflow, not tested for outcomes	Arklavo synthesis of catalog and variant study; measurement guidance	Not applicable to proposed workflow	2026-09-14
4	Order and replenishment	Can the exact quantities be delivered and reordered?	Dated quotation, supply confirmation and alternatives.	Proposed workflow, not tested for outcomes	Arklavo synthesis of catalog and variant study; measurement guidance	Not applicable to proposed workflow	2026-09-14

Record which requirements are essential and which are preferences. A brand shade might be an exact-match requirement in one program and a flexible preference in another. That distinction determines whether a missing combination requires a different garment, an alternate color or a documented exception.

Step 2: shortlist each required garment independently

Use the catalog table to identify candidate ranges, then inspect the exact product pages. Keep the style code and cut in the working record. “The company offers 6XL” is too broad to verify; a statement naming a style, color and label is much easier to check.

Review the garment most likely to constrain the program before approving all the others. If a jacket is mandatory, its range should be confirmed while the tee and polo choices remain adjustable. That approach follows from the category differences in this sample, but the actual ordering should follow the buyer's own requirements.

Step 3: calculate the intersection of the required combinations

For a fixed style and cut, the feasible palette is the set of colors that contain every required listed size. In the 3600 case study, a requirement for XS through 3XL leaves 46 observed colors. Adding 4XL leaves 35; requiring XS through 6XL leaves eight. These are set intersections within this one captured style. 5

For a program with multiple cuts or garments, repeat the check for each item. Then compare the named colors where a common palette is required. The current SanMar navigator counts cannot calculate that cross-garment intersection; more detailed product evidence is needed.

Step 4: check dimensions and samples

Distinguish a garment measurement from a body measurement. For example, the SanMar L100 specification page describes its garment bust measurement as a laid-flat measurement across the chest, while its separate size chart gives body bust ranges. Those fields have different definitions and should not be substituted for each other. 10

An assessment should use the exact garment's instructions, appropriate samples and the wearer's experience of movement and comfort. This report does not prescribe a measurement allowance or determine which size a person should choose. Those decisions depend on the garment and the person, not just on a label sequence.

Step 5: obtain commercial and replenishment confirmation

Ask for a dated response covering the exact combinations, quantities, decoration and delivery requirements. Record substitutions separately. A second color described as “close” should not silently replace an exact color if consistency is part of the brief.

For replenishment, keep the product identifiers and the confirmed alternatives with the program record. When the range changes, the record makes it possible to see which combinations require a new decision. This is a proposed documentation practice; the study did not measure how frequently any supplier changes its assortment.

A compact verification worksheet

8. Questions buyers and researchers ask

Does “available to 6XL” mean every color reaches 6XL?

No such conclusion follows from a style-wide maximum. In the 3600 snapshot, eight of 46 captured colors listed 6XL. The exact result is specific to that style and date, but it demonstrates why color-level checking matters. 5

Which plus-size uniforms were covered by this report?

The report inventories adult entries in three SanMar 2026 collections: tees, polos and outerwear, including the long-sleeve and vest entries they contain. It does not cover every supplier, every occupational uniform, trousers, footwear or a complete PPE system. The downloadable style table identifies every included entry. 4

Are women's cuts less available than standard or unisex cuts?

The selected documents show a lower share of explicitly women's entries reaching the stated 5XL threshold: four of 110, compared with 42 of 200 in the standard/adult/unisex/other group. That is a catalog-label observation, not a fit-adjusted national comparison. At the 4XL threshold, the category-level patterns are more mixed. 4

Can a standard or unisex garment replace a women's cut?

This study cannot decide that for a wearer. The catalog classification says what the supplier calls the entry; it does not establish equivalent dimensions, shape or preference. A program should assess the actual garment and avoid assuming that a different label alone resolves the requirement.

How many employees would these ranges fit?

The study cannot calculate that number. It contains catalog labels and variant records, not employee measurements or wearer tests. Dividing a size count by the number of employees would not produce a valid coverage estimate.

Are the listed combinations in stock today?

This report does not provide current inventory. Its observations were captured September 14, 2026, and its published matrix counts listed variants rather than stock flags. Confirm the particular quantities and delivery date with the supplier.

Did larger sizes cost more?

No matched commercial price study was conducted. The absence of a surcharge finding should not be interpreted as evidence that surcharges do or do not exist. A valid comparison would hold the style, color, quantity, decoration and other commercial terms constant.

9. Methods and reproducibility

Study design and frame declaration

This is a descriptive document audit with a nested product-listing case study. A read-only feasibility pilot identified sources with usable fields and established that the color-level question could be examined. The production protocol was then frozen before full collection and aggregate calculation. Pilot examples had already been seen; the study is not described as a preregistered experiment.

The three navigator frames were selected for category relevance and accessible, comparable documentation. Within each selected document, every adult product entry was inventoried. Explicit youth entries were retained in an exclusion table. The unit is document/category plus style code, so the results describe the documents rather than the full market or a supplier's entire website.

For the 3600 case, the first production page capture supplied the complete color-handle frame. Its observed count of 46 was not a sampling limit. Every distinct handle in that capture was retained. The raw page, frame export and individual product responses are preserved with hashes and capture information.

Field extraction and classification

Catalog rows were extracted from the original PDF text and reconciled by page. The retained fields include the exact style code, source size-and-cut phrase, normalized minimum and maximum labels, published color count, category and page number. Split rows were joined where a color count continued onto the next line. A photograph-only callout was logged separately to prevent duplicate counting.

The cut classification follows explicit row wording. Rows containing women's wording form that group; tall wording forms the tall group; youth wording determines exclusion. Remaining adult-context rows are grouped as standard/adult/unisex/other. The group name deliberately preserves uncertainty about unmarked cuts rather than inferring a gender from a style-code prefix.

The non-tall label order used for threshold calculations is XXS, XS, S, M, L, XL, 2XL, 3XL, 4XL, 5XL and 6XL. Each threshold tests the published maximum against the stated label. It does not assert that every color contains every intermediate size or that intervals between labels represent equal physical increments.

Calculations

For a catalog group, the reported percentage equals the number of parseable non-tall entries whose maximum reaches the threshold, divided by all parseable non-tall entries in that group. Tall entries are reported separately. No adult range or color-count values were missing in this capture; the calculation code retains missingness checks so that future gaps cannot disappear silently.

For the color case study, listing presence is defined by an individual product variant carrying the relevant size option. Every variant's style identifier was checked as 3600, and variant labels were reconciled with the product's option list. Variants were not filtered by public availability flags. The result is a binary listing matrix, with one cell for each captured color and size label from XS through 6XL.

The color percentage for a size equals the number of successfully captured colors containing that listed size divided by the number of successfully captured colors. All 46 captures succeeded, so there was no difference between the captured denominator and the frozen frame. A failed capture would have been reported as missing rather than converted to ten absent variants.

Source preservation and verification

The source ledger records requested and final URLs, capture timestamps, response status, available document headers, file sizes and SHA-256 hashes. Available Last-Modified headers are retained as technical metadata, not silently interpreted as editorial publication dates. Catalog edition, observation date and supporting-source dates remain separate fields.

Verification has two distinct layers. The research team's private source audit checks the archived source bytes before rebuilding the inventory, exclusions, page totals, threshold tables, color matrix and summary results. The public reader calculation script recomputes the derived tables and numerical results from the downloadable coded observations using Python's standard library. It does not require the publishers' archived pages or catalog files and does not authenticate those sources. Readers can inspect the original row text beside each coded value. The claim ledger maps headline calculations and documentary examples to their supporting table or source.

These checks address transcription, counting and reproducibility. They do not establish that the manufacturer's underlying product representation is complete in every commercial system, nor do they independently test the physical garments. Separate editorial review can improve the report's reliability but should not be confused with external academic peer review or a wearer study.

10. Limitations and interpretation

The most important limitation is the sampling frame. SanMar's navigators are curated commercial documents, and the manufacturer case study concerns one style. The results cannot estimate national prevalence, rank the entire industry or establish the share of U.S. workers whose uniform needs are met. Brands and styles outside the documents may have different offerings.

The documents also differ in composition. A category comparison combines different fabrics, constructions, cuts and brand selections. The standard/other and women's groups are not matched experimental sets. Differences in their published maxima are meaningful as catalog descriptions, but they cannot isolate the effect of a cut, a brand strategy or a production constraint.

The data are dated. A 2026 catalog can remain linked while particular product representations change. A current manufacturer page and a distributor navigator can reasonably have different scopes. Where representations disagree, this report preserves the distinction and avoids converting it into an unsupported historical explanation.

Size labels are incomplete evidence about fit. The audit does not contain a distribution of worker measurements, physical garment measurements across the whole sample, stretch behavior, post-laundering dimensions or wearer assessments. It cannot identify an adequate label range for every employer or determine an individual's size.

Operational information is also absent. We did not collect confirmed warehouse quantities, backorders, negotiated prices, decoration costs, minimum orders, replenishment performance or completed customer purchases. A listed combination is therefore not a fulfillment guarantee. A combination absent from a captured representation is not proof that no supply route exists.

Finally, the study addresses only one component of inclusion. A broad label range can coexist with difficulties involving shape, mobility, closures, comfort or access to a preferred cut. Conversely, a narrowly defined program may meet its particular wearers' needs with a smaller range. The appropriate assessment depends on those wearers and the work, not on a single catalog score.

11. Conclusion: a 2026 baseline for more precise uniform specifications

This 2026 report provides a dated baseline of 327 adult catalog entries and a complete 46-color listing study for one T-shirt style. Its central finding is that published size breadth changes with the threshold, the cut and the color being examined. In the selected non-tall catalog frame, 75.5% of entries advertised at least 4XL, while 14.8% advertised at least 5XL. In the 3600 case, all 46 colors listed through 3XL, 35 listed 4XL and eight listed 5XL and 6XL. 4 5

The practical response is to specify and verify the complete set of required combinations. Begin with current style-level evidence, move to exact color and cut records, check product measurements and samples, and obtain dated commercial confirmation. Keep the source and date with the decision so that a later change can be identified.

The report answers a defined question: which size ranges and color combinations appear in the selected catalog documents and product records? The 2026 dataset gives buyers a reference they can inspect and update as products change. Wearer assessment and supplier confirmation remain necessary before those documented combinations can support an actual uniform program.

Material requirements need their own documentation alongside size specifications. Our Sustainable Apparel Claims: The 2026 Evidence and Certification Report explains what product descriptions and certificates can establish.

Data, authorship and citation

Suggested citation: Arklavo Research. (2026, September 14). Size-Inclusive Workwear: The 2026 U.S. Catalog Availability Report. Arklavo. https://arklavo.com/blogs/custom-apparel-guide/size-inclusive-workwear

Arklavo commissioned this research and is a commercial apparel provider. The study uses public third-party catalog documents and product records; no supplier commissioned these findings. No external academic peer review, field study, wearer trial or completed-order audit is implied. Readers should distinguish the study's observations from the proposed procurement workflow.

Available research files:

• Complete adult catalog table, with exact source phrases and PDF pages.
• Full product inventory, youth-exclusion table and page reconciliation.
• Size-threshold calculations and maximum-label distribution.
• Complete 3600 size–color matrix, listed variants and frozen color frame.
• Source ledger, claim ledger, protocol, summary results and reader calculation script.

To verify the published arithmetic, keep results.json and the complete data folder beside reader_reproduce.py, then run:

python reader_reproduce.py

The script rebuilds the calculations from the coded observations and compares them with the supplied derived tables and results. It uses Python's standard library and makes no network requests. The private source-capture and extraction audit is a separate process: the reader check does not verify archived source hashes or authenticate publisher content. Full third-party source captures are not included in the public download.

When reusing a chart or statistic, retain its denominator, source frame and September 14, 2026 observation date. Do not relabel a catalog percentage as the percentage of employees who can be fitted. Source catalogs remain the property of their respective publishers; the downloadable coded observations and calculations identify those sources rather than reproducing their full designs.

References

1. SanMar. 2026 Tee Navigator. Six-page catalog, linked from the production navigator index and captured September 14, 2026. Original PDF.

2. SanMar. 2026 Polo Navigator. Eight-page catalog, captured September 14, 2026. Original PDF.

3. SanMar. 2026 Outerwear Navigator. Seven-page catalog, captured September 14, 2026. Original PDF.

4. Arklavo Research. Original coding and calculations from references 1–3, September 14, 2026. Catalog inventory, thresholds, cut summaries, page reconciliation and reader calculation script. This is analysis of the cited catalog frame, not a separate population survey.

5. Next Level Apparel; Arklavo Research. Official 3600 color product representations captured September 14, 2026; original listing matrix calculated from all 46 captured color handles. Frame product page, complete source URL list, variant observations and matrix. Each record identifies its official product source.

6. National Institute for Occupational Safety and Health. Anthropometry and Work: An Overview. April 10, 2024. CDC/NIOSH overview.

7. SanMar. Product Navigators. Production resource index, captured September 14, 2026. Navigator index.

8. Next Level Apparel. 3600 Cotton T-Shirt Sell Sheet. Copyright 2025; linked from the official product page at the September 14, 2026 capture. Official sell sheet.

9. Next Level Apparel. 2026 Next Level Apparel Catalog. Style 3600 entry and color-specific extended-size notes. Official 2026 catalog.

10. SanMar. Port Authority Women's Core Classic Pique Polo, L100: Spec Sheet and Measurements. Current page captured September 14, 2026. Product measurement and size-chart definitions.