Defining Durability: A Technical Guide to FR/AR Apparel for Safety Managers

Safety managers must consider material quality, proper maintenance, and long-term cost-effectiveness to ensure optimal protection.

• By Jeff DuLong
• Oct 15, 2024

In industries where fire and electrical hazards are a risk, the safety of workers depends heavily on the protective clothing they wear. Flame-resistant (FR) and arc-rated (AR) apparel are essential in safeguarding against potential life-threatening injuries. However, the effectiveness of this protective gear is not only determined by its initial quality but also by its durability over time. Safety managers, especially in the utilities, oil and gas, and electrical industries, must understand the key factors that influence the longevity of FR/AR apparel.

Material Considerations

Flame-resistant apparel is made to resist ignition and prevent the spread of flames, while arc-rated apparel protects against electrical arc flash hazards. Arc rating, measured in calories per square centimeter (cal/cm²), indicates a garment’s ability to withstand an electrical arc event without breaking open, igniting or causing burns.

The durability of FR/AR clothing largely depends on the materials used in its construction. Common materials include engineered cotton, Nomex, Kevlar, and blends of these fibers with other synthetics, each with strengths and weaknesses for durability. 

Engineered cotton, for instance, undergoes a chemical process to impart flame-resistant properties. While cost-effective—if not sourced from a reputable fabric manufacturer with a long-standing history of providing the industry with reliable materials—these types of fabrics can lose their flame-resistant qualities over time, especially if not properly maintained. On the other hand, inherently flame-resistant fibers like Nomex maintain their protective properties throughout the garment’s life, even after repeated washing and wear. These materials are also known for their exceptional strength, making them popular choices, especially for organizations that utilize industrial laundry rental programs.

The weave of the fabric also plays a significant role. For example, tighter weaves may provide greater resistance to wear and tear, making the garment more durable. Additionally, certain weaves can enhance the fabric’s ability to resist abrasion, further extending the life of the apparel. Talk to the fabric manufacturer or request more information from your garment provider about different weave options and their impact on durability. 

The National Fire Protection Association (NFPA) sets standards for both FR and AR apparel to ensure they provide adequate protection in hazardous environments, including NFPA 70E and 2112. Compliance with these standards is non-negotiable; however, ensuring that FR/AR garments remain compliant over time requires attention to their durability. As garments age and endure repeated laundering and exposure to harsh conditions, their protective properties can diminish if not sourced from a manufacturer with a proven history in the marketplace and product guarantees in place. It’s a safety manager’s job to stay vigilant in monitoring the condition of protective apparel and replacing garments that no longer meet the required standards.

Impact of Care and Maintenance Methods

One of the most critical aspects of maintaining the durability of FR/AR apparel is proper laundering. Incorrect washing methods can degrade the fabric and diminish the garment’s protective qualities. Safety managers should establish strict laundering protocols, whether the garments are washed in-house or by an industrial laundry service. It’s essential to use detergents specifically designed for FR clothing and to avoid harsh chemicals that can weaken the fabric. Additionally, following the manufacturer’s care instructions is crucial to preserving the durability and effectiveness of the apparel.

When sourcing materials for PPE programs, a critical specification to include is a guarantee from the fabric manufacturer that the FR protection will last the life of the garment. With more knockoff and unproven import materials entering the U.S. market, working with certified manufacturers with these guarantees in place will ensure that the protection characteristics of FR/AR apparel remain intact even if the fabric itself begins to show signs of wear and tear.

It’s important to know that the NFPA 70E standard only requires fabric to maintain the required standards after 25 wash and dry cycles, while fabrics that must adhere to the 2112 testing are required to meet standards set after 100 industrial laundering cycles.

Cost-Effectiveness and Durability

While durable FR/AR apparel may come with a higher initial cost, it’s important to consider the long-term value these garments provide. Investing in high-quality, durable protective clothing can reduce the frequency of replacements, leading to cost savings.

Safety managers should weigh the initial investment against the potential costs of frequent replacements and the risk of reduced protection from worn-out garments. Sourcing materials from fabric manufacturers with domestic facilities and customer service teams can ensure any issues and claims are resolved quickly and likely with no additional cost. Spending more upfront on durable apparel can result in significant savings over time, both in terms of direct costs and in minimizing the risk of workplace injuries.

Maintenance practices directly impact the cost-effectiveness of this specific type of PPE. By maintaining the integrity of the protective clothing, safety managers can ensure workers remain protected, minimizing the risk of costly accidents and injuries. Diligent maintenance, such as training on care and selecting the right laundering services, can also maximize return on investment.

Investing in high-quality FR/AR apparel and maintenance practices enhances safety as well as cost-effective protection. By prioritizing durability, safety managers can make the decisions that safeguard their workforce and uphold the highest standards.

This article originally appeared in the October 2024 issue of Occupational Health & Safety.