Molten Metal Protection


From casting, processing, fabrication to finishing, molten metal hazards including molten metal splash and sparks are among the top concerns for workers in mills, foundries and welding shops. Selecting the right molten metal protection can make the difference between any of the hazards faced in mills or shops on any given day becoming severe or fatal.

Thermal protection is National Safety Apparel’s original line of protective workwear going back to the company’s first products in 1935. As the company has evolved, so has our line of molten metal protective clothing. Our thermal protective gear for metal workers doesn’t stop at protection against molten metal splash and spark. Flame resistant protection as well as radiant and contact heat are part of our thermal protection products. These products also include solutions for hazards like heat stress and low-visibility issues in foundries and shops.

If you don’t find the thermal PPE that is suited to a specific industry, job, plant, or customer, reach out to our design team or a regional sales rep so we can work with you to find the right type of thermal PPE for the job.


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Molten Metal Splash


When water, moisture or any sort of liquid comes into contact with molten metal, it turns into steam and can create an explosion. This type of hazard exposes workers and anyone in the area to high temperature liquids and materials that can cause severe or fatal burns. In some cases, a hot furnace can be exposed to containers of water and not just molten metal to cause a splash or explosion. Splash and sparks can even stick to and burn through clothing if the right molten metal PPE isn’t selected by plants and workers. Molten metal splash is a hazard that could cause severe injuries and fatalities because any part of a metal workers body can be exposed to this hazard from head to toe. Not only can molten metal splash stick to the wrong type of clothing or PPE, but just being around molten metals, furnaces and equipment contribute to heat stress as well.




Both CARBON ARMOUR and CARBON ARMOUR Silvers provide protection against molten metal splash and burn hazards that metal workers may face on a daily basis. Silvers offer advanced radiant heat protection, but CARBON ARMOUR molten metal protection can be worn all day in control rooms and anywhere in mills thanks to vented designs and breathable fabrics. While Silvers offer additional protection reflecting heat away from the wearer, non-aluminized options are breathable and offer moisture wicking, quick drying comfort for flame resistant protection from the start to finish of any work day. Just like Silvers, non-aluminized options still provide molten metal splash protection and comfort from hoods to jackets and sleeves.


Radiant Heat


Metal finishing processes do more than just create molten metal splash and spark hazards. These processes give off radiant heat which can contribute to discomfort and eventually heat stress. Radiant heat resistance is provided in certain types of thermal PPE options, which CARBON ARMOUR Silvers provide. It’s important for thermal protective clothing to provide spark and molten spatter resistance as well as radiant heat protection with comfort being maintained while working on daily tasks and around any processing plant or shop.


Aluminized PPE


Molten metal splash and the heat from it can cause severe burn injuries to any part of your body. Aluminized apparel should be worn by molten metal workers to protect from radiant heat as well as molten splash and other thermal hazards.

Aluminized PPE includes high heat hoods, jackets, aprons, pants, leggings, gloves and more. The advantage of aluminized PPE for metal industry workers who face molten metal splash hazards are any particles or sparks from molten metal splash not sticking to the surface of the PPE and being flame resistant so it will not ignite or continue to burn when the heat source is removed.

Aluminized PPE also reflects heat away from the person wearing the protective apparel, which helps to reduce heat stress during tasks when exposed to these hazards. Each item of aluminized apparel must go through ASTM F955 for molten metal splash as well as ASTM F 1939 for radiant heat to be evaluated. CARBON ARMOUR Silvers provides increased protection from radiant heat, sparks, and molten metal splash hazards.


Heat Stress


Hazards like heat stress can lead to issues such as low productivity and performance that lead to mistakes on important tasks. Those mistakes can also make the probability of other hazards more likely to occur as well as performance and decision making affected by heat stress. The proper thermal PPE that National Safety Apparel is known for is an easy way to prevent heat stress from affecting metal workers and prevents further hazards from becoming issues as well.


Flame Resistant Base Layers


Moisture buildup and non-breathable next-to-skin garments are two big contributors that can cause heat stress. Metal workers are required to have flame resistant protection on every layer of clothing worn. Selecting high-quality flame resistant base layers can help prevent this. Moisture wicking, breathable flame resistant base layers are an easy choice to help reduce heat stress and its potential impact on performance and additional hazards.

CARBON AMOUR Base Layers are flame resistant, breathable and lightweight and offer fast drying, moisture wicking comfort to stay cool. When flame resistant protection is needed in a mill or foundry, base layers must also be flame resistant for complete protection and because temperatures in those areas are hot, you also need them to help keep you cool and not add to potential heat stress issues. CARBON AMOUR base layers help with prevention against both hazards. CARBON AMOUR systems allow you to layer for complete thermal body protection in mills and foundries.

Use Silvers and aluminized PPE for radiant heat protection over top of CARBON AMOUR jackets for molten metal splash and flame resistant protection, and use base layers for moisture wicking, heat stress resistance as well as additional flame resistant protection. Selecting the proper base layers worn under thermal PPE in steel mills can help reduce the hazard of heat stress while working on already dangerous tasks. National Safety Apparel’s CARBON AMOUR Base Layers allow you to have a layer beneath your needed thermal PPE that provides comfort and protection all day long.

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