Understanding Flame Resistant Fabrics:
A Complete Guide

What Are Flame Resistant Fabrics?

Flame resistant (FR) fabrics are materials engineered to resist ignition and prevent the spread of flames. They play a vital role in protecting end users from fire hazards and exposure to high temperatures. FR fabrics are incorporated in protective garments that are critical pieces of personal protective equipment (PPE) in many industrial settings, firefighting and emergency response services, and military operations.  

Definition and Importance of FR Fabrics

Flame resistant fabrics are designed to self-extinguish when exposed to flames, minimizing the risk of burns and injuries. Self-extinguishing means that while the material may ignite when exposed to a flame, the material will not continue to burn once the flame source is removed. A fabric that self-extinguishes buys the wearer more time to remove themselves from the flame source. 

Inherent Flame Resistant Fabrics: 
Some fibers are naturally flame resistant and are known as “inherent FR” fibers. Their flame resistance is an intrinsic property of the molecular structure of the fibers and cannot be removed, making them favored components in durable FR fabrics. Commonly used inherent fibers are modacrylics and aramids. Inherent fibers can be combined with other natural or synthetic fibers to create fabric blends. Those blends offer the best of each fiber’s benefits, such as the protective qualities of a modacrylic fiber and the comfort qualities of cotton. 

Inherent FR Fabrics at TenCate Protective Fabrics:
TenCate Protective Fabrics manufactures a variety of FR fabrics with inherent fibers, such as Tecasafe^® Plus, Tecasafe^® One, Evolv^®, Omniweave^™, and Genesis^®.  

These fabrics are valued for their durability and reliability, maintaining their protective properties throughout the service lifespan of the garment. Tecasafe^® Plus is made with modacrylic fibers. Omniweave^™ is a legacy product featuring a DuPont^™ Nomex^® construction, which is an example of an aramid fiber. Genesis^® is an alternative baseline fabric solution also made with aramid fibers. Learn more about Inherent FR Fabrics. 

Treated Flame Resistant Fabrics: 
Treated FR fabrics are flame resistant as a result of a chemical treatment applied to the fabric. These are produced by treating regular fibers with flame-retardant chemicals. Various fibers that are not inherently flame resistant, including cotton and  polyester, are used in treated FR fabrics. Treated FR fabrics offer flexibility in design and cost-effectiveness, making them suitable  for multiple applications. Learn more about Choosing Treated FR Fabrics.  

Importance of Quality Flame Resistant Fabrics

Flame resistant fabrics are essential for ensuring the safety and protection of workers in environments where fire and electrical hazards are prevalent. FR fabrics are a part of mandatory PPE in hazardous workplaces because they serve as a worker’s last line of defense in the event of a fire or electrical event. To be compliant with safety regulations and to ensure a strong safety culture, these workplaces must have their workers outfitted in FR garments. 

Reduce the Risk of Severe Injuries and Fatalities

FR fabrics can significantly reduce the risk of burns and other fire-related injuries by resisting ignition and being self-extinguishing. This protection can be crucial for saving lives and minimizing the severity of injuries in the event of a fire. FR garments are the last line of defense for workers exposed to flames or electrical arc hazards and are a critical piece of safety equipment. 

Comply with Safety Regulations and Standards

Ensuring compliance with industry standards and safety regulations is vital for any organization. Using high-quality FR fabrics ensures compliance with stringent standards such as NFPA 2112, NFPA 70E, and ASTM F1506. Compliance with these standards is essential for meeting performance requirements and ensuring the highest levels of safety in hazardous environments. At TenCate Protective Fabrics, our products either meet or exceed all applicable standards. Learn about NFPA 2112’s most recent update here. 

Build a Strong Safety Culture

Knowing that effective protective measures, including wearing the correct protective workwear, are in place fosters a safer and more secure work environment. For employers, investing in high-quality FR fabrics demonstrates a commitment to the well-being of their workforce, which can improve productivity and morale. Employers can be confident in the protection of their workforce, while employees gain assurance from the quality of their FR garments. When workers are engaged in their company’s safety culture and invited to give feedback on their protective workwear, they benefit from the knowledge that they are truly valued by their organization. Bolster Your Safety Strategies with Stress-Reducing Tips for Safety Managers. Learn more on how to bolster your safety strategies with Stress-Reducing Tips for Safety Managers. 

Enhance Comfort and Durability

Modern high-quality FR fabrics are designed to be both protective and comfortable. Lightweight, breathable materials can help workers perform their duties with less discomfort, even in demanding conditions. Comfort is also integral to safety by making it less tempting to adjust garments in noncompliant ways. The improper wear of FR garments, such as rolling sleeves or untucking shirts, can open workers up to much greater risk of injury or fatality in an incident. The enhanced durability of modern FR fabrics means they provide long-lasting protection, reducing the need for frequent replacements, which is better both for budgets and the environment. Discover the comfort and durability of our fabrics. 

Support Environmental and Economic Sustainability 

TenCate Protective Fabrics is committed to our sustainability journey. As our industry continues to innovate, sustainability will remain a core priority, both in terms of environmental impact and economic value. Our FR fabrics are designed for longevity, reducing waste and the need for frequent replacements, lowering long-term costs. Moreover, our manufacturing processes aim to minimize environmental impact, supporting broader corporate sustainability goals. Learn about how circularity in protective workwear will lead to a more sustainable future. 

Flame resistant fabrics are indispensable in high-risk environments, providing necessary, compliant protection with increased comfort and durability. TenCate Protective Fabrics continues to innovate and improve FR solutions, ensuring that our products meet the evolving needs of various industries. For more detailed insights into our flame resistant fabrics portfolio, click here. 

Types of Flame Resistant Fabrics at TenCate Protective Fabrics

Flame resistant (FR) fabrics are categorized based on their manufacturing process and properties. Understanding the different types of FR fibers and fabrics can help you choose the right material for specific applications and environments.  

Inherent Flame Resistant Fabrics

Because inherent FR fabrics are made with inherently flame resistant fibers that are engineered at the molecular level to be flame resistant, they offer consistent, durable protection throughout the lifespan of the garment in which they are used. 

Explore Our Inherent FR Products:

• Tecasafe^® Plus
• Tecasafe^® One
• Tecasafe^® 360+
• Omniweave™/Genesis^®
• Oasis^™
• Tuffweld^™
• Evolv^®

Here’s a quick rundown of our inherent FR products for industrial safety with some of their key features: 

Inherent FR fabrics are particularly suitable for environments where long-term, consistent protection is critical. For workers who must always wear FR but who face a relatively lower risk of an incident occurring, investing in inherent FR is an economical choice. Because the garment is less likely to need to be replaced frequently due to an incident, the cost is spread out over a longer garment lifespan, and the end user gains all the comfort benefits offered by modern inherent FR fabrics. For all the details on each of our inherent FR fabrics listed above, explore our inherent FR fabrics page. 

Treated Flame Retardant Fabrics

Treated FR fabrics are produced by applying flame resistant chemicals to fabrics based on cotton blended with polyester, para-aramid, or polyamide. The chemical treatment fully penetrates the fibers and is bonded throughout the entire fabric, rendering the fabric flame resistant for the lifetime of the garment. 

• FR-treated fabrics offer excellent protection against molten metal splashes. For this reason, protective clothing made with FR-treated fabrics is the standard solution in many steel and metal environments.
  
  
• In addition to protecting against flames and molten metal splashes, the chemical treatment also gives these fabrics adequate performance in arc flash protection. This is why markets like utilities and oil and gas use FR-treated fabrics. 

Treated FR fabrics are a good choice in industries where wearers are more consistently exposed to risk factors, such as sparks or molten metal splashes in welding activities. Because the garments will need to be replaced more frequently and treated FR fabrics are usually at a lower price point than inherent FR, it makes sense to choose treated FR fabrics for applications that necessitate higher garment turnover rates. Replacing more expensive inherent FR products at the same rates would be less cost-effective. 

Standards and Certifications

Achieving safety performance certifications is essential when ensuring the reliability of FR fabrics. At TenCate Protective Fabrics, we meet and exceed industry standards to guarantee maximum safety and performance. Our dedication to quality and compliance means our FR fabrics offer the protection wearers need while working in high-risk environments. 

Key Industrial Safety Protective Workwear Standards to Know

NFPA 2112: Standard on Flame resistant Clothing for Protection of Industrial Personnel Against Short-Duration Thermal Exposures from Fire.

• Overview: NFPA 2112 specifies the minimum performance requirements and test methods for flame resistant fabrics and garments used in industrial environments. It ensures that protective clothing can withstand short-duration thermal exposures from fire, providing critical protection to workers in hazardous conditions. Read about NFPA 2112’s latest version here. 
  
  
• Importance: Compliance with NFPA 2112 is crucial for industries like oil and gas, petrochemicals, and manufacturing, where flash fire risks are prevalent. Ensuring garments meet this standard helps protect workers from severe burn injuries and fatalities. 

NFPA 70E: Standard for Electrical Safety in the Workplace.

• Overview: NFPA 70E outlines the safety requirements to protect workers from electrical hazards, including arc flash and shock. It covers selecting, maintaining, and using personal protective equipment (PPE), including flame resistant clothing. 
  
  
• Importance: Compliance with NFPA 70E is essential for enhancing electrical safety in the workplace. It helps prevent injuries from arc flash incidents, which can cause severe burns and other serious injuries. FR fabrics that meet NFPA 70E standards are vital for electrical workers and others exposed to electrical hazards. 

ASTM F1506: Standard Performance Specification for Flame Resistant Textile Materials for Wearing Apparel for Use by Electrical Workers Exposed to Momentary Electric Arc and Related Thermal Hazards.

• Overview: ASTM F1506 specifies performance requirements and test methods for flame resistant fabrics and garments used by workers exposed to electric arc and related thermal hazards. This standard ensures that materials provide adequate protection and performance under specified conditions.
  
  
• Importance: Ensuring compliance with ASTM F1506 helps protect electrical workers from arc flash hazards. Garments that meet this standard provide reliable protection, enhancing worker safety and confidence in high-risk environments.

Additional Standards and Certifications for FR in Industrial Safety Settings

In addition to the key standards mentioned above, TenCate Protective Fabrics complies with a range of other industry standards and certifications both in the U.S. and abroad to ensure the highest levels of safety and performance across our global portfolio. Our products are rigorously tested and consistently meet or exceed these standards, providing reliable protection across various industries.

By adhering to these rigorous standards and certifications, TenCate Protective Fabrics ensures that our FR fabrics provide unmatched protection, durability, and comfort. We aim to lead our industry with an uncompromising commitment to safety and quality.

Cross-Segment Innovation

Flame resistant (FR) fabrics are essential in numerous industries and applications. They ensure safety and protection for all end users exposed to fire hazards. These fabrics provide critical protection, acting as the last line of defense for wearers. Garments made with FR fabrics are not just clothes, but key pieces of safety equipment.

Industrial Safety

Professionals working in oil and gas, electrical utilities, petrochemical, and other dangerous industries rely on FR fabrics. These environments can present significant fire and electrical risks, making high-quality FR fabrics essential for worker safety.

• Comprehensive Protection: Industrial safety fabrics must be designed to protect against a wide range of hazards, including flash fires, extreme heat, and electrical arc flash.
  
  
• Compliance with Standards: Industry safety regulations are in place to ensure that workers are protected according to the highest safety standards. Industrial protective workwear must comply with these standards.
  
  
• Comfort and Performance: Uncomfortable workwear can mean less-safe workwear. If workers are less distracted by discomfort caused by their PPE, they can perform their duties with greater efficiency, productivity, and most importantly, safety.
  
  
• Durability and Longevity: Industrial environments demand durable fabrics that can withstand continuous use and exposure to harsh conditions, as well as high-temperature industrial laundering.

Explore our industrial safety fabrics to learn how we protect workers in various industrial settings.

Cross-Segment Innovation

At TenCate Protective Fabrics, innovation doesn’t happen in silos. Our expertise across Emergency Response, Military, and Industrial Safety segments allows us to cross-pollinate advancements, ensuring that each industry benefits from the latest breakthroughs in fabric technology.

In the Emergency Response sector, firefighters rely on lightweight, breathable fabrics that enhance comfort without compromising protection. These advancements in moisture management and thermal regulation have influenced the Industrial Safety segment, where workers in extreme environments now benefit from increased breathability, helping them stay cooler and more comfortable on the job.

On the Military side, durability is paramount. Soldiers require rugged, high-performance fabrics that withstand the harshest conditions while maintaining flexibility and wearability. These innovations in strength and longevity have directly impacted industrial workwear, leading to more durable, longer-lasting protective fabrics that reduce replacement costs and enhance worker safety.

Similarly, developments in flame resistant technology—originally refined for military and emergency response applications—have translated into industrial workwear solutions that offer enhanced thermal protection, keeping workers safer in high-heat environments.

By leveraging advancements across these sectors, TenCate continues to push protective fabric technology forward. Whether it’s improved breathability, durability, or thermal performance, our innovations don’t just stay within one segment—they elevate protection and comfort across industries, creating a ripple effect of continuous improvement in safety and performance.

The Global Leader in Flame Resistant Fabrics: Where Innovation Meets Purpose

At TenCate Protective Fabrics, we are guided by our shared purpose of protecting the people that communities rely on. Our commitment to innovation, quality, and safety motivates us to continually develop improved products for the marketplace to give industrial safety programs a selection of high-quality protective, durable, and comfortable materials. These are some of the benefits of choosing TenCate Protective Fabrics products for your protective workwear needs:

Advanced Protection

Our FR fabrics are designed to provide the highest possible protection against fire hazards, meeting or exceeding relevant safety standards. Our fabrics’ advanced technology and materials ensure they perform reliably in the most demanding environments.

• Flame Resistance: Our fabrics are engineered to self-extinguish and prevent the spread of flames, buying the wearer critical time to get away from the fire source and significantly reducing the risk of burns and injuries.
• Thermal Protection: TenCate Protective Fabrics offers products with excellent thermal insulation, protecting wearers who work in the hottest environments from radiant heat exposure.
• Compliance with Safety Standards: Our FR fabrics meet and exceed stringent industry standards, ensuring maximum protection for workers in hazardous conditions.

Durability

TenCate Protective Fabrics’ products are known for their long-lasting performance and resistance to wear and tear, making them a cost-effective choice for protective clothing.

• Long-Lasting Performance: Our fabrics maintain their protective properties even after repeated use and high-temperature industrial washing, ensuring consistent protection over time.
• Resistance to Wear and Tear: Our fabrics are engineered to withstand harsh conditions and offer exceptional durability, reducing the need for frequent replacements.
• Reliable Protection: The durability of our fabrics ensures that they continue to provide reliable protection throughout their lifespan, giving users confidence in their safety gear.

Comfort

Safety is the number one priority, but comfort is an extremely close second. Ensuring our fabrics are comfortable to wear for extended periods is crucial to supporting their protective qualities by encouraging compliant wear. Focusing on comfort in developing advanced products helps improve not only worker performance and satisfaction but also safety.

• Breathability: Our fabrics are designed to be breathable, allowing air to circulate and keeping wearers cool and comfortable.
• Lightweight Design: Despite their protective capabilities, our fabrics are lightweight, minimizing the burden on the wearer and allowing for greater mobility.
• Softness and Flexibility: We offer fabrics with more softness and flexibility to enhance comfort, making them suitable for long shifts and strenuous activities.
• Ergonomic Fit: Our protective fabrics are designed to fit ergonomical garment designs, providing ease of movement and reducing fatigue.

Durability and Economic Benefits

TenCate Protective Fabrics is committed to maximizing product lifespans and the economic value of our products. Increased durability has the added bonus of reducing environmental impact, and globally, we are also committed to sustainability.

• Cost Effective: Our fabrics’ durability and longevity reduce the frequency of replacements, offering significant cost savings over time.
• Sustainable Practices: Our manufacturing processes are designed to minimize environmental impact and push the industry toward a more sustainable future while working toward our own broader corporate sustainability goals.
• Recycling Initiatives: We engage in recycling initiatives wherever we can and partner with a charitable organization to reduce materials waste and our environmental footprint, promoting a more sustainable future for the textiles industry.

By choosing TenCate Protective Fabrics, you invest in maximum protection, long-lasting durability, and exceptional comfort. Our dedication to quality and innovation ensures that our fabrics meet the highest safety and performance standards, making them the preferred choice for protective clothing across various industries.

Leveraging New Technologies

Industrial safety is constantly evolving, and at TenCate Protective Fabrics, we stay ahead by developing solutions that meet the changing demands of today’s workforce. Our latest innovations are designed to enhance both protection and comfort, ensuring that workers have the best possible gear for the job.

Casualization Movement

One of the biggest industry trends is the demand for greater mobility and flexibility in protective workwear. Tecasafe^® 360+ answers this need with built-in four-way stretch, offering unmatched comfort and freedom of movement while maintaining the proven durability and flame resistance that industrial workers rely on.

Going Ecogreen^®

Sustainability is another key focus, driving us to develop materials that reduce environmental impact without compromising performance. Tecasafe^® Ecogreen^® leads the way with a BCI^® cotton-based and recycled PET bottle blend, making it one of the most sustainable FR fabrics on the market while delivering the same trusted protection and comfort.

As industrial workplaces become more demanding, we continue to innovate with fabrics that are lighter, more breathable, and more durable than ever before. By listening to end users and adapting to industry trends, we ensure that our fabrics not only meet but exceed expectations.

At TenCate Protective Fabrics, innovation is never static. We’re committed to pushing the boundaries of safety, comfort, and sustainability, delivering next-generation solutions that keep industrial workers protected and productive.

Frequently Asked Questions (FAQs)

What Are Flame Resistant Fabrics?

Flame resistant fabrics are materials designed to resist ignition and self-extinguish in a set amount of time. These fabrics protect individuals working in high-risk environments with heat, fire, or electrical hazards, such as emergency response, industrial safety, military operations, and various industrial settings. Explore the TenCate Protective Fabrics fabric selector tool to find the best flame resistant fabrics for your needs.

How Do Flame Resistant Fabrics Work?

FR fabrics are made from a blend of either inherently FR fibers or a chemically treated FR fibers. Inherent FR fabrics are made from fibers that are intrinsically flame resistant, while FR-treated fabrics undergo a process that imparts flame resistant properties to the fabric through a chemical treatment. Both methods enable the fabric to self-extinguish when exposed to flames, meaning it does not continue to burn when the flame has been removed, which can help reduce injury.

What Standards Do Flame Resistant Fabrics Need to Meet?

FR fabrics must comply with various industry standards to ensure their effectiveness and safety. Key standards include NFPA 2112 for protection against short-duration thermal exposures, NFPA 70E for electrical safety, and ASTM F1506 for textile materials used by electrical workers. Meeting these standards helps ensure that the fabrics provide adequate protection and performance according to these governing regulations. If a garment does not meet the required standards for a specific application, it should not be considered compliant and it will not properly protect against the relevant risks.

Who Needs to Wear Flame Resistant Garments?

Government regulators determine whether flame resistant PPE is required for specific occupations based on the risks involved. In industries where workers face potential exposure to hazards such as flash fires, open flames, or electrical arc flashes, compliance with these regulations ensures proper protection. While comprehensive safety programs are designed to prevent such incidents, FR garments serve as the last line of defense when hazards do occur—playing a critical role in a worker’s ability to return home safely at the end of the day.

How Do I Purchase TenCate Protective Fabrics Products?

If you are an end user or a safety professional interested in ordering FR workwear made with TenCate Protective Fabrics materials, you can purchase garments constructed with our fabrics through a garment manufacturer or distributor. We do not sell protective garments directly to the market; we manufacture the fabrics that go into the garments. We can, however, answer any questions you may have about our products and help guide you through the process and make sure you get what you want. Reach out to us here.

What Are the Benefits of Using TenCate Protective Fabrics Products?

At TenCate Protective Fabrics, we pride ourselves on delivering not only the highest-quality protective fabrics possible in terms of safety, comfort, and durability, but we also offer top-of-the-class customer service and take a consultant approach to our role in the supply chain. When you partner with TenCate Protective Fabrics, you benefit from our team’s deep well of knowledge and experience in the safety industry.

We encourage you to reach out to us with any questions about protective fabrics, the market in general, industry trends, or your safety program at any time. We are always more than happy to discuss better safety strategies and ensure you have the information you need to make the best selection for your needs.

How Should Flame Resistant Fabrics Be Maintained?

Proper maintenance is crucial to preserving the protective properties of FR fabrics. For detailed maintenance guidelines for a specific product, refer to the care instructions provided by your garment manufacturer or distributor.

How Do You Know You’re Selecting the Right FR for Your Needs?

Proper FR garment selection is no easy feat, but it can be made simpler with these tactics:

Stay up to date with industry trends, updates, and standards by regularly attending trade shows, subscribing to relevant publications and newsletters, and staying engaged with your partners in the value chain. Then, when it’s time to order new FR workwear, you already have an idea of what’s available and don’t have to begin your research from scratch. Secondly, leverage the knowledge of partners at fabric manufacturers (like us) and garment manufacturers and distributors to help you get tailored information for your specific needs.

Third, ensure you have recently performed a thorough risk assessment to determine the risks you need to protect your workers against and look for products certified as compliant with the relevant standards. Using all three of these tactics in concert and keeping open lines of communication with your suppliers will help you make a confident decision.