When it comes to workplace safety, especially in high-risk environments like electrical or industrial work, protective gear is non-negotiable. But there's a common question among workers: Can I wear non-FR (flame-resistant) clothing under my FR gear? The simple answer is: No. Wearing non-FR clothing under your FR gear can compromise your protection in dangerous situations, including arc flashes or fire hazards. Here's why it matters and what you should wear instead.
Why Non-FR Clothing Under FR Gear Poses a Risk
The primary function of FR clothing is to provide protection against fire and arc flash hazards by preventing the material from catching fire easily. However, non-FR clothing - even if it is not made from a meltable material - can still pose significant risks in the event of an arc flash or flame exposure. Non-FR fabrics like cotton, polyester, and blends may ignite, melt, or catch fire, reducing the effectiveness of the FR outerwear.
When non-FR base layers catch fire, they can quickly burn, leading to severe injuries such as second- or third-degree burns. This is because non-FR fabrics are not designed to withstand the extreme temperatures that can occur during an arc flash.
In fact, studies and safety standards show that any non-FR clothing worn underneath protective gear may cause further harm in the event of an arc flash. The fire-resistant outer layer of your gear may be unable to stop the rapid spread of fire or molten fabric if non-FR layers are involved.
Best Base Layers for FR Protection
So, what should you wear under your FR clothing to maximize safety? There are three key options that align with safety standards and can improve your protection in high-risk environments:
1. Wear an FR-Rated Base Layer
The safest and most effective option is to wear an FR base layer. FR base layers are specifically designed to provide additional protection by resisting ignition, burning, or melting when exposed to flame or arc flash. These garments are tested to meet strict safety standards, ensuring they offer a protective barrier against both heat and fire.
FR base layers are made from materials like aromatic polyamides or modacrylic blends that are inherently flame-resistant, providing you with an added layer of protection that complements your FR outerwear. This type of clothing is especially important for workers in environments with a high risk of electric arc flashes or open flames.
2. 100% Cotton Base Layers
If you prefer not to wear an FR base layer, you can opt for a 100% cotton base layer. Cotton is non-meltable, which means it won't melt onto your skin in the event of an arc flash. While cotton offers some protection, it is still flammable, and an arc flash can ignite it.
The issue with cotton, though, is that if your FR outer layer is not worn properly - such as leaving the shirt untucked - the base layer can catch fire. This is why a properly worn FR outer layer is crucial, even with cotton base layers.
3. No Base Layer at All
Another option is to wear no base layer at all. If you choose this, ensure that your FR outer layer is worn correctly, including tucked-in shirts, buttoned cuffs, and the top button fastened. This will keep you compliant with the safety standards while ensuring your FR outerwear provides the full protection intended.
However, going without a base layer does expose you to the risk of injury if your outer layer shifts or becomes unbuttoned during the workday, so it’s not always the safest choice.
Why Avoid Non-FR Undergarments
If you decide to wear a non-FR base layer under your FR clothing, it can be dangerous. Materials like polyester, nylon, and other synthetic fabrics can melt when exposed to heat or flames, causing molten fabric to stick to your skin and lead to serious burns. This can happen even if your FR outer layer is perfectly rated and intact. When the base layer ignites, it compromises the protection that your FR outer clothing provides.
A non-FR base layer can dramatically change the outcome from a low-risk exposure to a life-threatening injury. During an arc flash, molten polymer from a meltable base layer can cause severe burns, even if the outer FR layer is intact.
Real-World Testing: Why FR Base Layers Matter
Independent testing has shown the consequences of wearing meltable or flammable undergarments under FR clothing. In an arc flash demonstration, workers wearing non-FR base layers experienced severe burns due to the igniting and melting fabric. On the other hand, workers in FR-rated base layers were protected from burns because the material didn't ignite or melt during the arc flash.
This demonstrates the critical importance of choosing FR-rated undergarments and properly wearing your FR outerwear to ensure the highest level of protection.
Final Thoughts: Always Choose FR Base Layers
While industry standards may not require a base layer for FR protection, wearing an arc-rated or flame-resistant base layer is the best practice for workers in high-risk environments. It adds an additional layer of safety and ensures you remain protected in case of an arc flash or fire hazard. Non-FR clothing, even if it's made of non-meltable fabric, can still present a significant risk to your safety.
To maximize your protection, opt for FR-rated base layers and ensure your FR gear is worn correctly. Doing so ensures you have the best possible defense against potential fire or electrical hazards.
Explore our range of FR-rated base layers and other safety gear today to stay safe in high-risk environments.