Does FR Clothing Lose Its Protection Over Time?

Author: Tara Safe

Flame-resistant (FR) clothing is a critical component of personal protective equipment (PPE) for workers in high-risk industries such as oil and gas, electrical utilities, welding, and manufacturing. Designed to provide protection against flames, arc flashes, and thermal hazards, FR garments help prevent severe burns and injuries. However, one common concern among employers and workers is whether FR clothing loses its protective qualities over time.

This article explores the factors that influence the longevity of FR clothing, signs of wear and degradation, proper maintenance practices, and when to replace worn-out FR garments.

How FR Clothing Works

FR clothing is engineered to resist ignition, self-extinguish when exposed to flames, and minimize the transfer of heat to the wearer’s skin. The effectiveness of FR garments depends on the type of fabric used:

  • Inherent FR Fabrics – These fabrics have flame-resistant properties built into their fibers. Examples include aramids (like Nomex) and modacrylic blends. The FR protection in these fabrics does not wash out or degrade significantly over time.
  • Treated FR Fabrics – These fabrics, often cotton-based, are chemically treated to provide flame resistance. Examples include FR-treated cotton and cotton-blend garments. The protective treatment can degrade over time due to washing, wear, and exposure to harsh chemicals.

    • Understanding the differences between these fabrics is crucial for assessing how FR properties may change over time.

    Factors That Affect FR Protection Over Time

    Several factors influence how long FR clothing retains its protective qualities:

    1. Type of Fabric

    Inherent FR fabrics maintain their protective qualities for the lifespan of the garment, while treated FR fabrics can degrade due to washing and environmental exposure. Repeated laundering, harsh detergents, and improper care can accelerate the loss of flame resistance in treated FR fabrics.

    2. Washing and Maintenance Practices

    Improper laundering is one of the biggest causes of reduced FR effectiveness. Common mistakes that can degrade FR properties include:

  • Using chlorine bleach or fabric softeners, which can break down the FR treatment.
  • Over-washing with aggressive detergents or industrial laundry methods that exceed recommended temperatures.
  • Failing to remove flammable contaminants, such as oil and grease, which can ignite and compromise the protective barrier.

    • To maintain FR effectiveness, workers should follow manufacturer-recommended washing instructions and avoid using non-FR-friendly cleaning products.

    3. Frequency and Intensity of Use

    Heavy usage in harsh work environments accelerates fabric wear and tear. Workers who are frequently exposed to high temperatures, sparks, or abrasive conditions may experience faster degradation of their FR clothing.

    4. Environmental Exposure

    Exposure to sunlight, chemicals, and extreme temperatures can weaken FR fabrics. Ultraviolet (UV) radiation from prolonged outdoor work can degrade fibers, while contact with industrial chemicals may reduce flame-resistant properties.

    5. Mechanical Wear and Tear

    FR clothing is subject to physical damage from abrasions, tears, and stretching. If the integrity of the fabric is compromised, its ability to provide adequate protection is diminished.

    Signs That FR Clothing Is Losing Its Protection

    Workers and employers should routinely inspect FR garments for signs of wear. Some indicators that FR clothing may need to be replaced include:

  • Visible fabric thinning – Worn-out or threadbare areas indicate material degradation.
  • Tears, holes, or fraying seams – These compromise the garment’s ability to shield against flames and heat.
  • Loss of fit – Stretching or shrinking may affect coverage and comfort, reducing protection.
  • Stubborn stains from flammable substances – If grease, oil, or chemicals cannot be completely removed, the garment may pose a burn risk.
  • Discoloration or fading – Excessive fading may indicate UV degradation or frequent washing with harsh detergents.
    • Best Practices for Maintaining FR Protection

    To extend the lifespan of FR clothing and ensure continuous protection, follow these best practices:

    1. Follow Manufacturer’s Care Instructions

    Each FR garment comes with specific laundering guidelines. Some general recommendations include:

  • Wash FR clothing in warm water (typically below 140°F/60°C).
  • Use mild, pH-balanced detergents without bleach, softeners, or starch.
  • Dry on low heat to prevent excessive shrinkage and fiber damage.
  • Avoid commercial dry cleaning, as some solvents can degrade FR properties.
    • 2. Inspect Clothing Regularly

    Conduct frequent inspections before and after each use to check for signs of wear and damage. If a garment shows significant wear, it should be retired from service.

    3. Remove Contaminants Promptly

    Oils, grease, and chemicals reduce FR effectiveness by acting as fuel sources in case of a fire. Washing garments as soon as possible after exposure helps maintain their protective qualities.

    4. Rotate Garments

    Wearing the same FR clothing daily leads to faster degradation. Using multiple sets and rotating them allows garments to last longer.

    5. Store Properly

    Store FR clothing in a cool, dry place, away from direct sunlight and chemicals that may cause damage.

    When to Replace FR Clothing

    While high-quality FR garments can last for years with proper care, all PPE has a limited lifespan. The following guidelines can help determine when FR clothing should be replaced:

  • Treated FR Fabrics – Typically last 1-3 years, depending on wear, washing frequency, and exposure to harsh conditions.
  • Inherent FR Fabrics – Can last up to 5 years or longer but should still be replaced if excessive wear is evident.
  • Frequent Repairs Needed – If a garment requires frequent patching or stitching, replacement is recommended.
  • Failed Arc Flash or Flame Tests – Some companies conduct periodic testing to ensure compliance. If garments fail these tests, they should be removed from service.
    • Regulatory Compliance and Industry Standards

    Employers must ensure that all FR clothing worn by workers remains compliant with industry regulations. Standards governing FR clothing include:

  • OSHA 1910.269 – Requires FR clothing for workers exposed to electrical arc hazards.
  • NFPA 70E – Provides guidelines for electrical safety, including arc flash protection.
  • ASTM F1506 – Establishes performance requirements for FR fabrics.
  • NFPA 2112 – Covers FR clothing for industrial flash fire protection.

    • Employers should conduct regular PPE assessments to ensure compliance and worker safety.

    While FR clothing is designed to offer long-lasting protection, its effectiveness can diminish over time due to fabric type, laundering practices, mechanical wear, and environmental exposure. Understanding these factors allows workers and employers to take proactive measures to maintain FR protection.

    By following proper care guidelines, inspecting garments regularly, and replacing them when necessary, workers can ensure they remain protected from fire hazards. A well-maintained FR program not only enhances safety but also ensures compliance with industry regulations, ultimately safeguarding lives in hazardous work environments.