Layer by Layer: Leveraging FR Clothing Systems for Hazard Protection and Comfort

Layering flame-resistant (FR) clothing has long been a best practice among industrial athletes. In addition to providing critical hazard protection, this tried-and-true strategy enhances user comfort by enabling industrial athletes to add or remove clothing layers as their activity level or the weather changes.

Base, middle and outer FR layers are equally important. Each serves its own purpose, so it is wise for lineworkers to own all three types.

Base Layer: Moisture Management
This next-to-skin garment layer wicks moisture away from the body, a function that becomes especially important in frigid conditions, lowering the user’s risk of chills and hypothermia by keeping the skin dry and warm. Base layers are offered in various fabric weights, with a general rule of thumb that the heavier the fabric, the warmer it will keep you – so long as it wicks properly.

Keep in mind, however, that the primary purpose of an FR base layer isn’t to increase your warmth. Beyond offering hazard protection, this layer is intended to pull moisture away from the skin. So, when shopping for an optimal base layer, choose a quick-drying garment that offers permanent moisture-wicking performance. Permanent moisture management is achieved through a blend of hydrophobic/water-hating and hydrophilic/water-loving fibers. Manufacturers that make claims about their fabrics’ moisture-management benefits but don’t use this type of fiber blend typically rely on topical finishes that will wash out over time, diminishing garment performance.

FR fabric blends with proven moisture-management properties are available from numerous industry vendors. As you spec and select garments, ask for this and other relevant data to help guide your purchasing decisions.

Middle Layer: Insulation
The middle layer of an FR clothing system also moves moisture, similar to a base layer, but its primary role is helping users retain their body heat. Essentially, the more efficiently this layer traps heat, the warmer you will be. Fabric weight can be adjusted by users to match changing conditions; this is where the art of layering truly begins.

Here is just one example: Your shift starts early in the morning, when temperatures will be their lowest for the day. You opt to wear a base layer, a heavier midweight layer and a protective outer shell, all appropriately rated for the hazard exposure. As your body warms and the ambient temperature rises, you decide to swap your midweight layer for a lighter option that still provides adequate flame protection.

Ideally, industrial athletes will own middle layers in various fabric weights, including a heavier FR fabric for colder weather, giving themselves the flexibility to add or shed layers for comfort. Remember to select middle layers that provide permanent moisture-wicking performance. As with base layers, this feature helps to ensure fabric stays dry even as temperatures and physical activity levels rise.

Outer Layer: Wind, Rain and Snow Protection
Your outer FR layer should be breathable and wick moisture, but more importantly, it must protect you from the elements. Any wind or water given the opportunity to penetrate inner garment layers can quickly chill you, making this layer especially critical during storms.

One common consumer mistake is choosing an outer FR layer that’s too heavy and/or doesn’t breathe well, trapping moisture inside and providing subpar protection from wind, rain and snow. Outerwear should allow moisture to escape while being lightweight enough to allow the user’s freedom of movement. An FR clothing system that includes an outer layer with permanent moisture-wicking performance can move moisture from one layer to the next until it evaporates into the atmosphere.

Conclusion
Moisture-wicking technology was initially developed to enhance athletes’ performance in extreme outdoor environments, keeping them cooler and drier in hot conditions and warmer and drier in cold ones. Today, industrial athletes – like lineworkers – can take advantage of moisture-wicking, high-performance FR garments and well-designed layering systems to help keep them safe and comfortable in hazardous outdoor work environments.

About the Author: Brad Sipe is the director of business development for Lakeland Fire + Safety’s HPFR Division and a 25-year veteran of the apparel industry. Reach him at bssipe@lakeland.com.

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Selection Tips for Base, Middle and Outer Layers

Base

• Choose a base layer with permanent moisture management, which will help to ensure full lifetime performance of the garment.
• An optimal blend of hydrophobic and hydrophilic fibers is key. This combination pulls and pushes moisture through the FR fabric so that it spreads and dries more effectively. Ask vendors for garment data – it’s available – and be sure to check labels to confirm fiber blends.

Middle

• For flexibility, select FR middle layers in different fabric weights. These garments can be swapped out as temperatures and activity levels change.
• Ensure middle layers provide permanent moisture-wicking performance.

Outer

• Choose outerwear that will adequately protect you from wind, rain and snow.
• Make sure the FR garment is lightweight, breathable and incorporates permanent moisture management.