Australia Post has suspended the rollout of its new high-visibility polo shirts after workers reported sunburn through the fabric, despite their SPF 50 rating.
Australia Post could be forced to scrap millions of dollars' worth of newly issued uniforms amid mounting safety complaints, only weeks after debuting its refreshed wardrobe. The controversy centres on high-visibility polo shirts intended for tens of thousands of posties and field staff.
Workers reportedly say the fabric is so lightweight that many of them have suffered significant sunburn while wearing it, prompting the organisation to suspend distribution of what was meant to be a flagship item in the updated uniform line.
Following an 18-month trial period, Australia Post began introducing a redesigned 80-piece clothing range across its 60,000-strong workforce in January, with full implementation scheduled for completion by March.
Nine Newspapers earlier had reported the sum could amount to a total of $5 million, but it's understood that figure is vastly overstated.
What's wrong with AusPost's new uniform?
However, within weeks of the nationwide rollout — reportedly costing millions — the company initiated a safety assessment of the polo shirt’s claimed SPF 50 protection after widespread complaints, The Age reported.
Staff reported not only sunburn but also that undergarments and tattoos were clearly visible through the material.
Key details of the supply agreement, including the manufacturer and overall contract value, have not been disclosed.
Victorian branch secretary of the Communication Workers Union, Troy McGuinness, warned the misstep could prove extremely costly, both financially and in terms of worker wellbeing.
“If they thought this was going to save them $5 million, this stuff up is going to cost them $25-$30 million,” McGuinness told The Age.
At a February 6 meeting between union representatives and Australia Post management, it was agreed that employees and subcontractors could continue wearing previous uniforms until at least March 30 while the new garments undergo review and further clarification is sought from the supplier regarding sun protection standards.
McGuinness said some workers had already been instructed to return or dispose of their old uniforms before the recall, leaving team leaders in certain cases to purchase non-branded, sun-safe hi-vis alternatives for staff.
He added that concerns about sun safety, quality, durability, sizing and overall functionality had been raised throughout months of testing, yet the rollout proceeded in January regardless.
“They were see-through, people got sunburnt, and they shrank in the wash,” McGuinness said.
“We had reports of posties getting sunburn through the shirts. We had posties coming back with sunburn on their backs and on their upper arms.
“Throughout the 18-month trial period, these issues were reported to them, and they ignored them.”
Australia Post stops uniform rollout
Australia Post confirmed that it had halted distribution of the polo shirt pending a formal review of its sun-protection performance.
"Australia Post regards the safety of our team members as our number one priority and we worked quickly to investigate concerns that have been raised regarding the new SPF50 graded polo shirts," they told Yahoo News Australia.
"Australia Post has engaged an official Australia Federal Government agency, ARPANSA (Australian Radiation Protection & Nuclear Safety Agency), to test the fabric to ensure it meets the SPF50 rating, which was part of our approved uniform design.
Team members have been directed not to wear the shirt and Australia Post has provided a number of alternative options until the new polo shirt is deemed safe, suitable and meets our quality expectations. Australia Post does not expect team members to wear anything that is unsafe."
Uniform requirements are tightly regulated in Australia for high-risk sectors such as construction, mining and logistics, where garments often function as personal protective equipment, including shielding outdoor staff from ultraviolet exposure.
Australia Post employs more than 34,000 staff directly and engages roughly 30,000 contractors, making it one of the country’s largest employers.
The high-vis polos were designed for routine use by posties, delivery drivers, van operators and other employees working outdoors.