Flame off: Getting the best flame-resistant clothing for your workforce

In industries that have fire and explosion hazards, one of the most important personal protective equipment (PPE) for workers is flame-resistant (FR) garments. These are crucial when your staff works in environments where they can be burned by electrical arcs, flash fires, and combustible materials. Knowing which FR garments can work best is essential knowledge for those assigned to procure these PPEs.  

With the right FR garments, industry professionals can handle dangerous jobs and worry less about potential hazards. That’s why it’s important to know how these FR garments can protect workers from these risks.  

In this guide, Canadian Occupational Safety discusses the nature and importance of flame-resistant clothing. We’ll offer useful tips on how to choose the best flame-resistant clothing in Canada for your staff. 

What is flame-resistant clothing and why is it important?  

Flame-resistant (FR) clothing or garments are made of special fabrics and coatings that can withstand high temperatures and resist getting ignited by combustible materials. What is flame-resistant clothing made of? The most common materials are flame-resistant fabrics like cotton, Kevlar, Modacrylic, and Nomex.  

FR clothing is not only important, but also critical for the safety and protection of workers in industries that have an inherently high risk of injury or even death from fires or thermal transfer. In these high-risk industries, FR clothing is not only recommended but also required by certain regulations in many industries. Regulations that require the use of FR garments in the workplace include:  

• Occupational Health and Safety Code – this requires employers to ensure that their workers wear FR clothing and other essential PPEs to protect against hazards like flash fires or arc flashes. 

• CGSB 155.20 - this is an important standard from the Canadian General Standards Board that governs workwear. CGSB 155.20 requires FR clothing to pass tests and meet minimum safety requirements to protect against flash fires from hydrocarbons and steam and extremely hot fluids. 

• Provincial and territorial laws – some provinces and territories have their own laws that are concerned with the proper use of FR clothing for local industries. For example, British Columbia has their own regulations that govern the use of FR garments to protect workers against flash fires, molten metal, welding activities, and other thermal-related hazards.  
   

Industries that use FR clothing 

The industries that have burning hazards from electrical arc flashes, welding activities, working with molten metal, flash fires, and other tasks are those that need FR clothing most. Here are some of the industries where the use of flame-resistant clothing is crucial for workers’ safety:  

• Electric utilities and power generation – Workers in this industry definitely need FR garments, since they run the risk of electric arc flashes in their work environment. An arc flash can result in severe burn injury, as these phenomena can produce temperatures of more than 35,000 F. 

• Oil and gas – those working in this industry are constantly exposed to hydrogen sulfide, petrochemicals, and different chemical vapours – all of which are flammable. 

• Metalworking industry – workers in high-risk environments like smelting plants are exposed to electric arcs, molten metal, and very high temperatures that could simply ignite non-FR clothing. 

• Construction workers – as these workers use a lot of heavy machinery and work with flammable materials, FR garments serve as vital protection against accidental fires, arc flashes, or sparks. 

• Food processing – heavy machinery and equipment used in cooking, canning, and other food processing activities can expose workers to high heat and pressure.  

• Papermaking industry – this industry involves risk of fires due to flammable materials, combustible dust, and flammable chemicals.  
   

Keep in mind that these are but a sample of the many industries that require flame-resistant garments. If you are in doubt as to whether your staff will need them, you can consult or hire a safety professional to determine exactly what types of PPE your staff need.  

Don’t forget also that FR clothing can be a small part of the total safety kit your workers need. Take the time to practice due diligence and refer to CCOHS standards and regulations to round out your PPE list. 

Flame-retardant vs. Flame-resistant: what’s the difference? 

In your effort to find the best flame-resistant clothing in Canada, you may come across a similar-sounding term: fire retardant. It’s important to know their subtle differences.  

Flame-retardant 

Also called fire-retardant, this property refers to fabrics and garments that are coated with special flame-retardant coatings. It is critical to note that fire-retardant fabrics and clothing will burn but protect the wearer by burning at a significantly slower rate than untreated clothing.  

Flame-retardant qualities are classified into three categories:  

• flame retardant (FR) 
• inherently flame retardant (IFR) 
• durably flame retardant (DFR) 

Flame-resistant 

Flame-resistant or fire-resistant garments are typically made of synthetic fibres that resist catching fire despite prolonged exposure to direct flame or intense heat. Due to their construction, these are sometimes referred to as inherently flame-retardant fabrics. Instead of burning, they eventually melt.  

Depending on the product and its manufacturer, the degree of inherently flame-resistant fibres within an FR fabric can vary from a small percentage to being fully made of flame-resistant material.  

Choosing between flame-retardant and flame-resistant garments depends on the nature of the fire hazards and intensity of the temperatures. Other critical considerations are the frequency of exposure to fire and fire hazards. 

For instance, flame-retardant clothing is more effective and applicable for those in industries that have intermittent exposure to flames, such as the food processing or oil and gas industry.  

On the other hand, flame-resistant clothing is more suited for workers engaged in industries or professions where their exposure to flames is constant, such as firefighters, welders, and electricians. 

Differences between flame-retardant and flame-resistant safety garments

What does flame-resistant mean? 

Another important item to remember is that flame-resistant or flame-retardant clothing does not mean that the wearer is completely impervious to flame or its effects.  

Anyone who wears flame-retardant clothing should be aware that this type of PPE only serves as a temporary protective layer. Flame-resistant clothing that shields them from high temperatures, open flame, or catching fire due to an explosion will burn, but prevents immediate burn injury. 

A wearer of flame-resistant clothing likewise only has temporary protection from fires, explosions, or electrical arcs. This type of clothing is designed to melt. Either type of garment is designed to protect the user by burning off or melting away after getting exposed to flames. This is preferable to ordinary clothing that, when ignited, will continue to burn and seriously injure workers.  

While these seem to provide minimal protection, it is better to wear them rather than not having anything to protect workers from immediately suffering serious burns. In case of a fire, workers should always follow fire safety and evacuation protocols even when wearing these PPEs.  

What are the standards for flame-resistant clothing or garments? 

When choosing flame-resistant clothing for your organization, you may refer to these standards as your guide:  

1. Canadian Standards Association Z462 

Compliance with this standard is critical for workers who work with electrical safety hazards. CSA standard Z462 is chiefly concerned with Electrical Safety in the Workplace. This is especially useful in providing guidance on the selection of the appropriate electrical PPEs and other safety devices for electrical and maintenance personnel.  

2. National Fire Protection Association (NFPA) 2112 Standard 

Although this is an American organization, the NFPA 2112 is very useful as it specifies the minimum requirements for fire-resistant clothing. This standard covers the construction, design, evaluation, and certification of flame-resistant garments. It also provides guidance for the following qualities of flame-resistant clothing:  

• ASTM F2700 for heat transfer performance  

• ASTM F1930 for the manikin test  

• ASTM F2894 for heat and thermal shrinkage  

• ASTM D6413 before and after 100 wash cycles  

• ASTM D7138 Method B for thread melt 

3. Canadian Standards Association (CSA) Z96  

This standard governs the use of High-Visibility Safety Apparel (HVSA), which typically has flame-resistant qualities for use in hazardous environments. CSA Z96 is an especially important standard to use as reference when procuring PPEs for ensuring workers’ flame protection and giving them high visibility. Apply this standard when sourcing PPEs for workers in construction or road maintenance.  

Performance and testing requirements 

These different safety standards in Canada are applied to flame-resistant clothing. FR clothing in Canada must pass evaluations such as:  

• Flame resistance – assesses the fabric’s capacity to withstand catching fire and ability to self-extinguish once a heat or flame source is removed  

• Thermal protection – measures the garment’s ability to protect against extremely high temperatures; this is crucial to preventing severe burns resulting from exposure to open flames  

• Durability – refers to the garment’s ability to keep its flame-resistant properties even after multiple washes and uses 

What is the arc rating and why is it important? 

An arc rating is the measure of how well the fabric of flame-resistant clothing protects its wearer from the heat and pressure of an arc flash. The arc rating is measured in calories per square centimeter (cm2). It is a key factor in measuring the level of protection that a piece of FR clothing provides.  

A higher arc rating simply means that the clothing offers a higher level of protection. When checking the arc rating of an FR garment, take note there are four levels or categories of protection:  

• Hazard/Risk Category level 1 (HRC1) requires a minimum arc rating of 4 cal/cm2 

• Hazard/Risk Category level 2(HRC2) requires a minimum arc rating of 8 cal/cm2 

• Hazard/Risk Category level 3 (HRC3) requires a minimum arc rating of 25 cal/cm2 

• Hazard/Risk Category level 4 (HRC4) requires a minimum arc rating of 40 cal/cm2 

Arc flashes can produce temperatures of over 35,000°F in a matter of seconds, which can instantly burn skin and clothing. They can also generate an explosive pressure wave and a bright flash that can cause temporary or permanent blindness.  

Why are FR garments so expensive? 

The high cost of flame-resistant clothing is due to their special materials, manufacturing processes, and rigorous testing to pass strict quality and safety standards. These are PPEs that are designed to withstand high temperatures and flames, protecting the wearer from serious injuries or possibly even death.  

Maintaining your flame-resistant clothing 

To ensure that your FR remains in tip-top shape, washing your FR clothing is recommended but with certain precautions. Here’s how to maintain your FR garments:  

• Wash your FR garments separately from other clothes.  

• Turn the FR clothing inside-out before washing to help preserve the reflective material and reduce streaking.  

• Use warm water to remove dirt and grime. The hottest temperature you can use is often indicated on the clothing care label.  

• Don't use chemical bleach, strong detergents, laundry soaps, or fabric softeners; these can damage the clothing or affect its FR coatings.  

• Don't spray insect repellents like DEET directly on the FR clothing; this can make the clothing more flammable.  

• Don’t use hard water, as this can cause a buildup of calcium and magnesium salts, which can be a fuel source if the clothing catches fire.  

• Don't over dry the clothing as this can cause excessive shrinkage. Remove the clothing from the dryer while it's still damp, or line-dry it to avoid shrinkage.  

• If the clothing has stains, have it dry-cleaned. 

• Don’t reuse the clothing if it’s been exposed to a flash fire or other thermal event. 

• While you can repair a damaged FR garment, check with the manufacturer’s recommendations first. 

Flame-resistant clothing examples 

Here are a few examples of reliable and reputable FR clothing brands. You can do your due diligence or research on other viable options.  

Westex® DH Antistat 6.5 oz Insulated Bib Pant – Style 225 

Key features:  

• Provides an additional layer of safety with antistatic properties 
• Made of 48% Lenzing lyocell, 39% modacrylic, 12% aramid, and 1% carbon, ensuring inherent flame resistance while offering protection against static discharge 
• Provides wealth and comfort in cold weather 
   

J. J. Keller® SAFEGEAR® PPE   

This is an entire line of category 1 and 2 FR clothing, including base layer short- and long-sleeved T-shirts, high-visibility vests and sweatshirts, coveralls, jeans, a work shirt, and a balaclava. 

Key features: 

• flame-resistant and arc-rated, providing protection against flash fires and arc flashes 
• complying with OSHA standards 1910.269 and 1910.252 
• This line is in partnership with DRIFIRE, a leading brand in flame-resistant (FR) apparel, to expand its range of protective clothing.  
   

Dickies FR pants for men 

Key features:  

• 100% cotton, machine-washable 
• Arc rating 39 - HRC3 
• Dual tool pockets on side 
• Zip to knee leg opening, heavy duty brass zipper 
• Insulated quilt lining 

Choosing the right PPE for your workforce, like FR clothing, is a critical aspect of workplace safety. Be sure to diligently research the best options so you can make informed choices. Remember that the FR garments you source for your workforce ensure their safety, protect your company’s reputation, and ensure compliance with state and federal safety regulations. 

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