Why Proper Cleaning of FR/AR Workwear Matters: Protecting Performance, Comfort, and Worker Safety

Learn why proper laundering of FR/AR workwear is critical for worker safety, garment longevity, and protection performance, with expert guidance from Coats.

As temperatures rise and job sites get messier, from spring mud and summer sweat to grease, oils, and industrial residues, workwear takes a serious beating. For workers in electrical utilities, oil and gas, manufacturing, and other high-hazard industries, FR (Flame-Resistant) and AR (Arc-Rated) garments are a critical line of defence. Yet one of the most overlooked aspects of PPE management is what happens after the shift ends: how these garments are washed.

Improper laundering is one of the leading causes of premature garment failure and reduced protective performance. And in high-hazard environments, that’s not just a cost issue, it’s a safety issue.

FR/AR Workwear Is Not Ordinary Clothing

Unlike everyday clothing, FR and AR garments are precision-engineered technical products. Every component, from the base fibre and yarn construction to the weave structure and finishing treatments, is designed to perform a specific protective function. These garments are tested and rated to meet standards such as:

• NFPA 70E (Standard for Electrical Safety in the Workplace)
• NFPA 2112 (Standard on Flame-Resistant Clothing for Protection of Industrial Personnel Against Short-Duration Thermal Exposures from Fire)
• ASTM F1506 (Performance Specification for Flame Resistant and Arc Rated Textile Materials)
• CGSB-155.20 (Canadian General Standards Board standard for flame resistant clothing)

When these garments are washed improperly, their engineered properties can be compromised, often without any visible sign of damage. A garment that looks clean may no longer meet the performance thresholds it was rated for.

The Do’s and Don’ts of FR Garment Care

FR materials afford workers serious protection from serious risks, so taking serious care of them is essential to ensure they continue performing for the full-service life of the garment. The following guidelines reflect best practices for laundering, maintaining, and inspecting IFR workwear.

✔ DO: Wash Your FR Regularly

When your FR garment has been exposed to particulate matter, oils, chemicals, or other contaminants, it must be thoroughly cleaned before the next use. The garment is rated flame resistant; those contaminants are not.

✖ DON’T: Wear Dirty FR

FR fabrics protect wearers by self-extinguishing; they stop burning when a flame source is removed. But if the flame source is a burning oil stain on the fabric itself, that source cannot be removed. Always launder contaminated garments before re-wearing.

✖ DON’T: Wait to Wash

When a garment is soiled, wash it as soon as possible. Allowing stains or substances to set into the fabric compromises its protective capacity. If significant oil contamination occurs on the job, the garment should go directly into the wash, not be worn again before laundering.

✔ DO: Use an Industrial Laundry Program When Possible

Industrial launderers follow validated best practices for washing and drying FR fabrics and removing hazardous contaminants. Industrial laundries utilize equipment and procedures that are more consistent and do not over dry garments in comparison to home laundering, making them the appropriate choice for heavy or chemical contamination. Industrial launderers can also repair or replace damaged garments using the correct FR-compatible materials. It is the employer’s responsibility to ensure PPE is properly maintained; an industrial laundry program is an excellent way to meet this obligation.

✖ DON’T: Use Cleaning Products That Degrade FR Properties

If home washing is used, avoid products that compromise FR performance. Your garment manufacturer should provide specific guidance, but the following are commonly flagged:

• Soaps (salts of fatty acids) – can form insoluble soap scum in hard water, leaving flammable residue on fabric
• Chlorine bleach (sodium hypochlorite) – can affect fabric colour and structural strength
• Hydrogen peroxide – can affect fabric colour and strength
• Optical brighteners – can alter fabric colour and may affect performance
• Fabric softeners (liquids and dryer sheets) and laundry additives – can adversely affect flame resistant performance
• Starch and stiffeners – should only be used after testing their impact on FR properties

✔ DO: Use Softened Water

Hard water contains mineral salts, calcium and magnesium, that combine with fatty-based soaps to form insoluble deposits on fabric. These deposits accumulate over time and can adversely affect FR characteristics. Using softened water reduces detergent consumption, improves wash quality, and protects garment integrity.

✖ DON’T: Wash FR in Mixed Laundry Loads

Sort FR garments from regular laundry and wash them separately. Also separate by fabric type and weight, light vs. dark colours, and degree of soiling. Cross-contamination from non-FR fibres, such as flammable lint, can attach to FR fabric and ignite in a flash fire event, directly negating the garment’s protection. Conversely, chemical contaminants from FR workwear should not be transferred to household laundry.

✔ DO: Respect Washing and Drying Temperature Guidelines

Always wash and dry FR garments at the temperatures specified on the care label. Using incorrect temperatures can cause shrinkage, affect fit, and leave gaps in coverage. A shrunken garment that no longer fully covers exposed skin should not be worn on the job, just as a garment with holes should not be.

✖ DON’T: Wear FR Around Strong Acids Without Caution

Acids such as hydrochloric or sulphuric acid may degrade the tensile strength of cotton and cellulosic fibres, potentially causing holes in the fabric. While strong acids may not always directly affect FR protective properties, physical damage to the garment increases exposure risk in a thermal incident.

✔ DO: Always Follow Your Garment Manufacturer’s Instructions

The above guidelines reflect general best practices applicable to many types of FR workwear. However, they should never supersede the specific laundering and maintenance instructions provided by your garment manufacturer. For questions about care, repair, or end-of-life criteria, your manufacturer is your primary resource.

Home Laundering vs. Industrial Laundering: What You Need to Know

Home Laundering

Home laundering is acceptable for many FR garments, provided correct protocols are followed consistently. Key considerations include:

• Use mild, phosphate-free detergents, avoid soaps, softeners, bleach, and optical brighteners
• Wash with softened water wherever possible
• Follow care label temperature guidelines, use warm, not hot water
• Tumble dry on low heat or air-dry; avoid over-drying
• Wash FR garments separately, never in mixed household loads

The limitation of home laundering is consistency. Workers may not always follow protocols, and detergent choices vary. Over time, small deviations accumulate and can accelerate garment degradation.

Industrial Laundering

Industrial or commercial laundering services that specialize in FR workwear offer a more controlled and consistent cleaning environment. These facilities use validated wash formulations, controlled water temperatures, and standardized drying cycles designed to preserve FR performance, and can handle levels of contamination that home machines cannot.

For large workwear fleets, common in utilities, oil and gas operations, and industrial facilities, industrial laundering is often the most practical and performance-preserving solution. It also transfers maintenance accountability to a specialist, supporting employer compliance obligations.

One important consideration: some FR garments use topical moisture-management finishes applied to the fabric surface. These finishes can diminish with repeated washing, regardless of how carefully the garment is laundered. In contrast, garments built with inherent performance characteristics, where moisture management and flame resistance are integrated into the fibre structure itself, maintain their functionality far more reliably across the garment lifecycle.

The Engineering Behind Wash-Durable FR Performance

Not all FR fabrics age equally. The durability of a garment through repeated laundering is directly influenced by how it was engineered at the yarn and fibre level.

Fibre blend optimization plays a significant role. Blends of inherently FR fibres, such as modacrylic, aramid, or FR viscose, combined in the right proportions deliver protection that remains stable wash after wash, without depending on applied chemical treatments that degrade over time.

Yarn construction also matters. The way fibres are spun and plied affects how the fabric responds to the mechanical stress of laundering. Tightly engineered yarn structures are more resistant to fibre breakage, pilling, and fabric distortion, all factors that affect both protection and wearer comfort.

This is an area where Coats brings deep technical expertise. Coats’ FlamePro™ FR fabric range is engineered with these durability considerations built in, using carefully optimized fibre blends and yarn architectures designed to maintain both protective performance and comfort through the rigors of industrial laundering cycles.

The goal is simple: FR protection that works on day one should still work on day 500.

Practical Guidance for Safety Managers and EHS Professionals

Maintaining a compliant, high-performing FR workwear program requires more than purchasing quality garments, it requires an ongoing commitment to proper care. Here’s what safety managers should implement:

• Establish a Garment Inspection Routine: Inspect FR garments regularly for tears, thinning fabric, seam damage, fading, or contamination that cannot be fully removed. Any garment with compromised integrity should be removed from service immediately.
• Provide Worker Training: Ensure all workers who wear FR/AR garments understand basic care requirements. A laminated care guide posted in locker rooms or break areas is a simple, effective tool.
• Document Laundering Procedures: Whether garments are laundered at home or through a facility, establish written guidelines. This is particularly important for maintaining certifications during audits.
• Work with Suppliers Who Offer Technical Support: Garment suppliers and fabric manufacturers should be partners in your PPE program, providing laundering guidance, wash-cycle performance data, and end-of-life replacement criteria.
• Replace Garments on Schedule: FR garments have a defined service life. Establish and enforce replacement schedules based on manufacturer guidance, launder cycle counts, or inspection findings.

Conclusion: Garment Care Is Part of the Protection System

In industries where workers face the risk of flash fires, arc flash events, and thermal hazards, FR and AR workwear can mean the difference between a close call and a life-altering injury. But a garment’s protection is only as reliable as the care it receives.

Proper laundering preserves the engineered performance that makes FR workwear effective. It extends garment life, maintains compliance with NFPA and ASTM standards, and supports worker comfort, all of which contribute to a safer, more cost-effective workwear program.

High-quality FR solutions are designed to retain their performance through repeated laundering cycles. By choosing fabrics engineered for inherent durability, and by following the Do’s and Don’ts outlined above, safety managers and workers can be confident that the protection they relied on yesterday will still be there tomorrow.