How High-Visibility Clothing Reduces Accidents on Worksites: 5 Key Benefits You Should Know
22/12/2025
Retire or Repair? 5 Signs Your FR Workwear Is No Longer Safe
19/02/2026
Imagine walking onto a rig or into a high-voltage zone thinking you are protected, only to find out your safety gear has failed because of how it was washed last Sunday.
It is a terrifying thought, but it happens.
As a leading Industrial Workwear Manufacturer, we at ACI Workwear know that the technology behind Flame Resistant (FR) Clothing is robust—but it is not indestructible. Whether you are in the Mining Industry, Oil & Gas, or Electrical Industry, the way you wash your gear determines if it saves your skin or adds to the injury.
Improper maintenance doesn’t just fade the color; it can strip away the self-extinguishing properties of the fabric.
Key Takeaways
- Treat Gear as PPE: Your FR clothing is a life-saving device, not just a uniform; improper care can strip away its self-extinguishing properties.
- The “Never” List: Never use chlorine bleach (destroy fibers) or fabric softeners (adds flammable fuel) on FR garments.
- Isolate Your Load: Always wash FR workwear separately to prevent flammable lint from regular clothes (like cotton towels) from sticking to the gear.
- The Golden Rule: To maintain NFPA 2112 compliance, use mild liquid detergent, wash in warm water (max 140°F), and inspect garments regularly for damage.
The 7 Big Mistakes and How to Fix Them
Below, we break down the 7 most common laundry mistakes that destroy FR protection and exactly how to fix them.
1. Using Chlorine Bleach
Why it’s a mistake:
Chlorine bleach is chemically aggressive. For FR-treated cotton (like Proban or Pyrovatex fabrics), bleach attacks the molecular bond between the flame-retardant chemical and the cotton fiber.
The Result:
After just a few washes with bleach, your “FR” shirt becomes standard cotton. If an arc flash or flash fire occurs, the fabric will ignite and continue to burn, offering zero protection.
Tip: Even “color-safe” bleach can be risky depending on the formulation. Stick to mild liquid detergents specifically labeled as free from bleach and hydrogen peroxide.
2. Adding Fabric Softeners or Dryer Sheets
Why it’s a mistake:
Fabric softeners work by coating fibers with a thin layer of waxy chemicals to make them feel smooth. These chemicals are often petroleum-based and highly flammable.
The Result:
When you use softener on FR & Arc Resistant Clothing, you are essentially coating your safety gear in fuel. This “masking” effect prevents the FR fabric from doing its job. In a fire event, the softener layer burns first, potentially triggering the fabric underneath to burn as well.
Avoid: Liquid softeners, dryer sheets, and 2-in-1 detergents with built-in softeners.
3. Washing FR Gear with Regular Laundry
Why it’s a mistake:
It’s tempting to throw your work coveralls in with your jeans and towels to save time. However, standard fabrics (especially cotton and poly-blends) shed lint.
The Result:
Lint from non-FR clothing can get trapped in the weave of your High Visibility Safety Apparel or FR coveralls. This lint is not flame-resistant. If an arc flash occurs, the lint creates a “surface of fire” across the garment, increasing heat exposure to the wearer.
Rule: Always wash Industrial Uniforms separately from personal clothing.
4. Using Hard Water or Soap-Based Detergents
Why it’s a mistake:
“Soap” and “Detergent” are not the same thing. Soaps are made from natural fats and can react with minerals in hard water to form “soap scum” (insoluble salts).
The Result:
These mineral deposits (calcium and magnesium salts) build up on the fabric over time. Just like lint, these deposits are flammable. If your facility is in a region with hard water (common in many mining and industrial zones), this buildup can ignite during a thermal event.
The Fix: Use synthetic liquid detergents (not soap bars or flakes) and consider adding a water softener if your water supply is heavy in minerals.
5. Washing at Extremely High Temperatures
Why it’s a mistake:
While industrial workwear is tough, boiling it is unnecessary and harmful. Washing at temperatures above 140°F (60°C) can cause excessive shrinkage.
The Result:
Shrinkage is a safety hazard. If your FR coverall sleeves shrink by two inches, your wrists are now exposed. In an arc flash or chemical splash event, exposed skin is the first point of severe injury.
Target Temp: Warm wash (approx. 120°F – 140°F) is the sweet spot for removing industrial oils without damaging the fit.
6. Using Starch or Insect Repellents (DEET)
Why it’s a mistake:
Starch is a carbohydrate—a fuel source. Insect repellents containing DEET are highly flammable.
The Result:
Ironing starch into your uniform adds a flammable layer, similar to a fabric softener. Spraying DEET on your clothing is even worse; DEET effectively turns your shirt into a torch.
Alternative: If you work in Agriculture or Outdoor Construction and need bug protection, use Permethrin-based sprays (applied correctly) or non-flammable alternatives, but never DEET directly on FR gear.
7. Ignoring Repairs or Using Non-FR Thread
Why it’s a mistake:
When a button pops or a seam rip on your Cold Protective/Freezer Clothing, sewing it up with standard polyester or cotton thread compromises the garment.
The Result:
Standard thread melts or burns instantly. In a fire, the seams of your repaired gear will fail, causing the garment to fall open and exposing your body to the hazard.
The Fix: Only repair FR clothing with matching FR materials (fabric and thread). If the damage is significant, retire the garment immediately.
The 7 Deadly Sins of FR Laundry
|
The Sin |
The Danger |
The Solution |
|
Bleach |
Breaks down FR molecular bonds |
Use mild liquid detergent only |
|
Fabric Softener |
Coats fibers in flammable wax |
Use dryer balls for softness |
|
Regular Laundry |
Contaminates gear with flammable lint |
Wash FR loads separately |
|
Hard Water |
Leaves flammable mineral deposits |
Use water softeners |
|
Hot Water (>140°F) |
Shrinks gear, exposing skin |
Wash Warm (120°F-140°F) |
|
Starch/DEET |
Adds fuel to the fabric |
Avoid completely |
|
Standard Thread |
Seams melt and burst open |
Use certified FR repair kits |
The Correct Way to Wash FR Clothing (Step-by-Step)
To maintain the integrity of Safety Workwear Suppliers‘ products, follow this simple routine:
- Empty Pockets: Remove tools, pens, and debris.
- Zip Up: Close all zippers and Velcro to prevent abrasion.
- Turn Inside Out: This preserves the color and reflective tape on High Visibility Clothing.
- Load Separately: Do not mix with personal clothes.
- Add Detergent: Use mild, liquid, non-bio detergent.
- Wash: Select “Normal” or “Cotton” cycle with Warm Water.
- Dry: Tumble dry on Low Heat or hang dry in the shade (UV light can degrade some fibers over time).
Why ACI Workwear? Quality That Lasts
At ACI Workwear, we understand that in the Steel, Chemical, and Railway Industries, your uniform is your last line of defense.
As a premier Industrial Workwear Manufacturer, we engineer our garments—from Arc Resistant shirts to Cold Storage jackets—to withstand rigorous industrial use. However, even the world’s best gear needs proper care.
We use high-grade materials that meet international standards (NFPA 2112, EN ISO 11612). By following the care guide above, you ensure that the premium protection we build into every stitch remains active for the life of the garment.
Looking for certified safety gear? Explore ours FR & Arc Resistant Range here.
Frequently Asked Questions (FAQs)
1. Can I wash FR clothing at home?
Yes, you can wash FR clothing at home if you follow strict guidelines: wash separately, use warm water, use mild liquid detergent, and strictly avoid bleach and fabric softeners. However, for gear heavily soiled with toxic chemicals or heavy industrial oils, professional industrial laundering is recommended to prevent contaminating your home washing machine and other family laundry.
2. How many washes does FR clothing last?
This depends on fabric technology. Treated FR fabrics (like chemically treated cotton) typically retain their protection for 50–100 washes if care instructions are followed. Inherent FR fabrics (where the polymer itself is non-flammable, like Nomex®) last for the entire life of the garment, provided they are not physically damaged or ripped.
3. Does dry cleaning damage FR clothing?
No. Dry cleaning is often the most effective method for removing heavy grease, tar, and oil that water-based washing cannot remove. However, you must ensure the dry cleaner does not use “re-deposition” agents or starch. Always check out the specific care label on your ACI Workwear garment before sending it out.
4. When should I retire my FR workwear?
You must retire and replace your FR gear immediately if:
- It has holes, tears, or frayed edges that cannot be safely repaired with FR materials.
- It is stained with flammable substances (like fuel, paint, or solvents) that do not wash out.
- The fabric has become thin, “threadbare,” or brittle from UV exposure.
- It accidentally came into contact with chlorine bleach.
5. Can I iron my FR work shirts?
Yes, you can iron FR garments to maintain a professional appearance, but you must use a low temperature setting. Never use spray starch or sizing additives while ironing, as these add a flammable coating to the fabric that can ignite during an arc flash event.
6. Can I have my company logo embroidered on FR uniforms?
Yes, branding is important for corporate identity, but it must be done correctly. The embroidery must use a flame-resistant thread. Using standard polyester or rayon thread for logos creates a burn hazard; in a fire, the logo could melt into the wearer’s chest. Always request FR embroidery from your Industrial Workwear Manufacturer.
7. What should I do if my FR clothing gets soaked in oil or flammable chemicals?
If a garment is saturated with flammable liquids, it acts as a fuel source regardless of the FR fabric underneath. Remove the garment immediately. If the stain cannot be completely removed after specialized industrial laundering, the garment is no longer safe and must be discarded. Do not wear FR clothing that smells of fuel or has visible oil spots.
