Combat Heat Stress with Smarter FR Clothing Choices

When the temperature climbs, the wrong gear can turn a tough job into a dangerous one. Heat stress isn’t just uncomfortable, it leads to slower work, more mistakes, and higher safety risks. For safety managers and crews alike, it’s not just about staying cool, it’s about staying sharp, safe, and productive.

That’s where high-performance FR clothing makes the difference. Old-school, heavy PPE traps heat and makes it harder for workers to do their jobs. Today’s crews need gear built for the heat, not just for compliance. In this blog, we’ll cover what to look for in flame-resistant clothing and how modern solutions help teams stay protected without sacrificing comfort.

Heat Stress Isn’t Just a Summer Problem

Heat stress can happen in any season, even during cooler months. The real risk isn’t always the outdoor temperature, it’s the environment where the work is being done. Indoor job sites like steel mills, oil and gas refineries, or boiler rooms often hold heat and lack proper airflow. Even with air conditioning, enclosed areas near furnaces, electrical panels, or heavy equipment can stay dangerously hot.

Heat stress happens when the body can’t cool itself down fast enough, causing fatigue, confusion, and in severe cases, heat stroke. According to the Bureau of Labor Statistics, environmental heat exposure contributed to over 400 worker deaths between 2011 and 2021. Many of those occurred in settings not typically associated with extreme heat. That shows just how deceptive this hazard can be.

In addition to dehydration and exhaustion, workers may also experience mental fog or poor motor control. These symptoms can lead to dropped tools, missteps, and slow reactions, all dangerous when working at heights, with heavy machinery, or near live electricity. Understanding these risks is important, but it is just as critical to recognize how the wrong gear can quietly make them worse.

PPE Can Protect, or Make Things Worse

When workers are required to wear PPE, they’re often layering over other clothing. This can trap body heat, making it harder for sweat to evaporate. In jobs where workers wear flame resistant clothing for long periods of time, the buildup of heat inside the garment can cause core body temperature to rise steadily, even if the ambient temperature feels manageable.

Many older FR garments were built for durability, not thermal comfort. While they meet safety requirements, they can trap heat and restrict airflow, making it harder for the body to stay cool. That discomfort doesn’t just lower morale, it increases the chance that workers will adjust or remove their gear, adding unnecessary risk.

If PPE feels too hot or restrictive, workers may roll up sleeves, unzip jackets, or skip layers altogether, exposing skin and raising the risk of injuries. The solution is gear that doesn’t force a choice between safety and comfort. High-performance FR clothing does both, which is why managing heat stress effectively starts with knowing what to look for in the right gear.

What to Look for in High-Performance FR Gear

Not all FR gear is built the same, and the right choice comes down to the details. Here’s what to look for when choosing gear that keeps workers both safe and comfortable.

Lightweight Protection

Fabric technology has come a long way. Inherently flame resistant materials like modacrylic blends or aramid fibers offer the same arc flash and flash fire protection at significantly lower weights compared to traditional FR clothing. For instance, some FR work shirts weigh as little as 4.4 ounces per square yard and still meet NFPA 70E, NFPA 2112, and ASTM F1506 standards. That lightness makes a big difference during a 12-hour shift.

Breathable Materials

Not all breathability is created equal. Look for FR garments engineered with mechanical stretch or open knit weaves. These design choices let hot air escape while still blocking heat and flame. It’s a balance between safety and airflow. Garments that breathe well reduce the chance of trapped sweat, which can lead to heat rash or bacterial growth on the skin, especially in high-humidity environments.

Moisture Wicking Technology

Wicking fabrics have improved a lot in recent years. The best ones now pull moisture away in seconds and spread it across the outer layer of the fabric where it evaporates faster. Some materials also include anti-odor treatments or antimicrobial finishes, which can help when changing clothes mid-shift isn’t practical.

Smart Design

Design features make or break comfort. Shoulder seams moved forward reduce chafing under a harness. Underarm gussets give workers better range of motion when reaching overhead. Mesh panels placed strategically at the back or sides of the garment help dump heat without weakening protection. When a garment fits and moves with the body, workers stay focused longer and are less likely to make comfort-related adjustments that reduce protection.

Choosing the right features is only part of the equation. To truly protect workers in high-heat environments, you need gear from a brand that puts performance and comfort first.

Why DRIFIRE Makes a Difference

Heat stress doesn’t give second chances. That’s why the gear you choose has to work with your team, not against them. DRIFIRE FR clothing is made to keep workers cool, dry, and protected when the job gets tough.

Our fabrics are lightweight, breathable, and built to move, without giving up an inch on safety. What started as military-grade tech now keeps crews safe in refineries, utility yards, and industrial plants every day.

If your team faces the heat, give them the gear that’s built for it. Choose DRIFIRE and fight heat stress with confidence.