Jun. 30, 2025
Flames leaping from clothing. Blinding smoke fills a room. The crackle of fabric burning. For most of us, this is the stuff of nightmares.
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But for those who work in high-risk industries, the threat of fire is all too real.
Every day, workers are critically injured or lose their lives to quickly spreading flames and deadly smoke. The battle against fire hazards rages on.
But the materials that makeup what we wear don’t have to leave us defenseless. Modern flame retardant textiles are fighting back, resisting ignition, and slowing fire spread to save lives and property.
Specially engineered and treated fabrics are beating back the flames.
However, not all fire-resistant materials are equal.
How do we know which ones provide enough protection when lives are on the line?
Today we’ll be uncovering the hidden methods and meticulous laboratory testing used to evaluate fire-safe textiles.
We’ll expose why vertical, 45-degree, and horizontal test methods reveal different performance insights.
You’ll discover how standardized combustion analysis combined with full-scale mannequin trials are helping develop state-of-the-art workwear that turns the tables against serious burn risks and workplace accidents.
The battle with fire dangers wages on, but flame-resistant textiles are fighting back harder than ever.
And this is their secret weapon…
Flame retardant fabrics are textiles that have been treated or are inherently resistant to catching fire and slowing the spread of flames. Essentially, it makes them more difficult to ignite and helps them self-extinguish once removed from a fire source.
Now, they aren’t completely fireproof, but rather fire resistant. If exposed to an open flame or intense heat, flame-retardant fabrics char rather than burst into flames. This charring creates a barrier that blocks oxygen and slows burning.
Some common examples of flame retardant fabrics are fabrics used for:
– Workwear and protective clothing
– Uniforms
– Furniture and upholstery
– Curtains and drapes
– Bedding and sleepwear
Well, as you can imagine, if these fabrics don’t perform as expected when exposed to flames or heat, the results could be catastrophic, especially for protective gear and clothing. Hundreds of serious injuries and deaths occur each year due to burns from quickly spreading fires.
By thoroughly testing textiles, manufacturers can ensure a basic level of fire safety for their products to help prevent accidents. Certain industries even require flame resistance testing by law before fabrics can be used.
Now that we know why testing is critical, let’s look at some of the most common test methods and standards around the world.
When it comes to official standards for testing, there is quite a bit of variation around the globe based on each country’s specific laws and regulations. However, while the exact details may differ, the test methods fall under a few main categories.
The key aspects evaluated when testing flame retardancy are:
– Ignition – how easily does the fabric catch fire
– Combustion – how quickly do flames spread across the surface
– Heat release – how much heat is emitted when burned
– Damage – the extent of charring, holes, melting, dripping
Keeping those factors in mind, let’s break down the major standards starting with Europe.
In the European Union, flame retardant standards are developed by CEN, the European Committee for Standardization, and focus heavily on:
– Protective clothing
– Workwear
– Uniforms
The main standards are:
These dictate test methods as well as performance requirements related to flame spread, damage, charring, melting, and ignition. Materials must meet specific criteria to be certified as compliant.
For example, EN classifies flame-retardant protective clothing into 3 categories based on thermal performance. The higher the class, the more protective the garment.
All EU standards utilize ISO test methods, which measure vertical and surface flame spread. Fabrics are exposed to a standard flame for a set time, then ignition speed, damage, and charring are evaluated.
So in summary, Europe focuses heavily on protective clothing and uses primarily vertical test methods.
Shifting gears to China, the main standards are GB .1- and GB - which cover:
Similar to Europe, these use vertical test methods, albeit with different instruments and performance criteria. China also utilizes the 45-degree angle test per GB/T which exposes samples to flames approaching from a diagonal direction.
GB--
This test determines flame spread rate, damage area, char length, and number of flame contacts before self-extinguishment. It evaluates factors beyond just vertical ignition, providing a more complete picture.
So China relies on vertical tests but also incorporates a 45-degree angle method for a wider evaluation.
In the US, standards focus specifically on protective clothing for dangerous industries where fire hazards are very real.
The National Fire Protection Agency has created a series of standards centered around NFPA – the benchmark for flame-resistant garments. It dictates requirements for workwear safety.
NFPA utilizes ASTM D vertical tests to measure char length, after-flame duration, damage, and melting behaviors. Like China, the US also incorporates a mannequin-based test that collects data on heat transfer and thermal shrinkage.
This full-scale evaluation provides additional insight beyond small swatches. Garments must meet minimum performance levels related to heat resistance.
Beyond the key geographies we just covered, other global regions rely on similar vertical and horizontal test methods, including:
So while specific instrumentation and limit values vary slightly, most global standards test flame retardancy using either vertical or horizontal methods aligned to ISO standards.
Now that we’ve compared the standards, let’s dive deeper into some of the most common test procedures and methodologies.
There are two main types of flame resistance tests:
Let’s break these down in detail…
Combustion tests analyze how a textile burns when exposed directly to a standard flame. The key characteristics evaluated are:
These tests focus specifically on fire interaction without external factors.
Combustion methods fall into 3 main orientations:
Let’s examine each one…
In vertical testing, fabric samples are mounted upright and ignited from below by a gas burner flame. The flame is applied for a predetermined time, and removed, and then factors like char length, afterglow, and burn time are analyzed as the sample self-extinguishes.
This orientation is most common and simulates exposure to fire approaching from a vertical direction, much like standing near the base of upward-spreading flames. It evaluates flammability and fire damage.
Steps of the Vertical Flame Test
The vertical flame test, also known as ASTM D, is an important test method used to determine the flame resistance of textiles. This test simulates exposure to an electric arc flash and measures how well a fabric resists burning.
When conducting ASTM D, a 12-inch long specimen of the test fabric is secured in a chamber, with the bottom cut edge exposed. This edge is then subjected to a standardized methane flame for 12 seconds. During and after this exposure, trained technicians record observations about the fabric’s reaction to the flame.
Specifically, they measure:
Afterflame – the time in seconds that visible flames remain on the fabric after the ignition source is removed
Afterglow – the time in seconds that a glowing persists after flames extinguish
Char Length – the length in inches of fabric damaged or destroyed by the flame
Melting/dripping – notations on whether the fabric melts or drips due to heat
The test is repeated five times on different fabric specimens, and the results are averaged to account for variability.
Compliance criteria are based on the char length measurement. For example, ASTM F states that to pass, a fabric’s average char length must not exceed 6 inches. NFPA sets an even more stringent limit of 4 inches maximum char length.
ASTM D provides a standard, controlled way for laboratories to evaluate and compare the flammability of textiles intended for protective clothing applications. The test yields quantitative data to determine if a fabric meets the flame resistance required by various industry safety standards.
Now let’s compare that to the 45-degree angle method…
As the name suggests, this test angles textile swatches at 45 degrees and ignites them from below, with the flame moving upwards diagonally along the surface.
Unlike vertical testing, flames come in contact with fabric samples for extended durations until reaching an endpoint.
Factors like char length, damage area, hole formation, and flame persistence are measured to determine fire safety. Since the flame contact timeframe is longer, 45-degree testing provides more data on material behavior and combustion characteristics.
This method is most commonly used for carpet testing and simulates fire spreading across horizontal surfaces where orientation to the heat source varies.
Steps of the 45 Degree Flammability Test
The 45-degree Flammability Test is designed to evaluate how quickly and intensely a textile sample burns, as well as the extent of fabric damage. There are three key aspects analyzed in this standardized test:
A textile specimen is placed at a 45-degree angle in the instrument and exposed to an ignition flame for 1 second. Technicians measure the time it takes for the upward-burning flame to travel a specified distance. Faster travel times indicate more intense burning. Visual cues like surface fluttering also signify intense combustion.
Again angled at 45 degrees, the fabric sample is ignited. Technicians record the duration of afterflame and afterglow once the ignition source is removed. They also measure the total area and length of fabric damage post-combustion.
As the sample burns up towards a marker placed 90mm from the bottom end, technicians count the number of times the advancing flame makes contact with the sample. More flame contacts signify faster upward burning.
To perform the test, the fabric specimen is hung at a 45-degree angle in the instrument chamber. The ignition flame is applied for 1 second, starting a timer. The test ends when the fabric burns through, dropping a weight that stops the timer.
Technicians observe the burning behavior and inspect for signs of melting or incomplete combustion. Multiple specimens are tested, averaging results.
The 45-degree test provides quantifiable metrics on a textile’s flammability under a standardized test method. The data can determine if a fabric meets flammability requirements for various safety standards and regulations.
Finally, let’s examine the last major orientation – horizontal…
In horizontal testing, textiles are oriented parallel to the ground and ignited from one end, with fire spreading outwards across their length horizontally.
The flame spread rate, heat release, burn distance, and burn time metrics are gathered as the fire moves over the surface.
This mimics conditions like drapes or upholstery igniting and burning laterally. horizontal test data helps assess factors like flashover risk as textiles get involved in a fire scenario.
To perform any of these combustion tests properly, specialized instrumentation is used to carefully control variables and collect accurate measurements.
Temperature, flames, timing, and mounting are all regulated to minimize deviations.
Steps of the Horizontal Flammability Test
The horizontal flame test provides a standardized procedure to evaluate how rapidly flames spread across the surface of textiles. This method determines the flame resistance of fabrics intended for protective clothing applications.
Test Specimen
Unless otherwise specified, the test fabric sample should measure 4.5 x 12.5 inches, with the longer dimension oriented parallel to the warp direction. Some fabrics demonstrate directional burning behavior, so technicians align the sample accordingly.
Pre-Testing
Before testing, the textile specimen is suspended vertically and heat conditioned in a circulating oven at 140-145°F (60-63°C) for 4 ± 0.25 hours. Conditioning removes any surface moisture that could influence results.
Test Procedure
Using specialized clamping holders that secure the long edges, technicians mount the fabric in a frame that tensions a 2-inch wide x 12.5-inch length center strip. The holder positions the specimen just inside a test cabinet, with clearance at the ends.
After a 2-minute reconditioning period, the holder is partially withdrawn and the methane burner flame is adjusted to 1.5 inches high. The specimen is then moved into the test position, with its end suspended 0.75 inches above the burner nozzle, and ignition takes place.
Flames are allowed to spread 1.5 inches before starting a timer. Technicians record the number of seconds required for the advancing flame front to traverse the remaining 10 inches of the exposed fabric strip.
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Test Results
Shorter times indicate a faster spread of flames across the surface. This quantifiable passing time data allows evaluation and comparison of horizontal flammability for textiles used in protective garments.
Flammability testing yields quantifiable performance metrics to judge a fabric’s reaction to fire. But visual observation before, during, and after testing also provides valuable insights. Technicians should record key details on the test specimen’s burning behavior to augment instrumental data.
Observations During Testing
First, the standard 10-second direct flame application allows side-by-side visual comparisons between fabrics. Subtle differences in ignition time, flame intensity, dripping behavior, and surface distortion can indicate relative flammability.
Measurements After Flame Exposure
Once the heat source is removed, trained technicians time and annotate several phenomena:
Afterflame – The number of seconds a visible flame remains on the fabric surface. Afterflame duration correlates to self-extinguishing characteristics.
Afterglow – The number of seconds a red heat persists after visible flames are extinguished. Glowing remnants may re-ignite under some conditions.
Hole Formation – Holes over 5mm in diameter suggest fabric break-open and potential body burn-through. Larger, more numerous holes signal inferior materials.
Char Length– Technicians tear the fabric on the most damaged axis and measure the length of char formation in inches or centimeters. Char length serves as a key flammability benchmark for protective clothing standards.
Recording first-hand observations, even on instrumented tests like vertical or horizontal flammability, provides additional insight into a fabric’s real-world protective performance in a flash fire event.
Next, let’s move beyond just combustion to performance testing…
While combustion testing reveals how textiles directly interact with fire, performance metrics evaluate fabric behavior when exposed to heat and flames in simulated use-case scenarios.
The goal is to understand real-world protection abilities like protective clothing.
Some common performance tests are:
– Thermal heat transfer
– Heat resistance
– Flame impingement
– Molten metal splash
Let’s explore a few…
This test uses specialized thermal mannequins with internal heaters and sensors. Flame-resistant garments are dressed onto mannequins, and then exposed to intense external heating meant to simulate proximity to extreme fires.
Sensors gather data on factors like:
– Heat transfer rate
– Temperature rise
– Burn progression rate
– Fabric integrity loss
Such testing provides lifesaving data for protective clothing design and standards compliance.
Next up is heat resistance testing…
Fabrics intended for high-temperature applications like fire blocking need proper heat performance data.
Testing involves subjecting materials to increasing temperatures while monitoring:
– Shrinkage
– Tensile strength
– Color change
– Dimensional stability
Exposure methods include:
– Open flame
– Radiant heat
– Forced hot air
Temperatures often exceed 500°F+ replicating extreme environments near molten materials and fire.
These tests help qualify which textiles withstand prolonged heat contact without failure while supporting the creation of safety standards.
And last but not least – direct flame impingement testing…
Here, specific regions of garments and gear experience direct contact with calibrated flames, unlike whole-sample combustion methods.
After flame exposure, factors like char depth, hole formation, and damaged area are measured.
This data verifies real shielding capacity against fire threats and validates minimum durability essential for occupational protective equipment.
Mimicking live fire dynamics makes standards more meaningful.
So in summary…
While combustion testing provides basic flammability data, performance metrics offer life-saving insights on real-world protection for situations like emergency response and proximity firefighting.
Combining Both Testing Modes for Complete Evaluation
As we’ve discussed, combustion and performance offer complementary datasets for holistic evaluation:
Combustion testing delivers fundamental flame retardancy metrics on ignition potential and fire spread characteristics. This allows fabric classification and treatment assessment.
Performance testing goes further to simulate protective barrier effectiveness when subjected to heat fluxes and direct fire contact. This enables product standards, specifications, and code compliance.
Together, they provide actionable intelligence for development, safety regulation, and quality assurance.
Additional Test Methods
Now besides the major methods we just outlined, there are a few additional niche tests worth mentioning such as:
Each has specific applications depending on product requirements:
For example, bedding and sleepwear focus heavily on toxicity risks and wash durability.
Medical materials may demand stringent chemical testing. Carpet backings use after-glow time limits to enforce fire blocking.
So that covers the basics of flame retardant test methods and global standards!
And there you have it – a crash course overview on flame retardant textile testing!
I hope you now have a solid grasp of the different methods used and what they help evaluate.
There’s real complexity and sophistication behind the scenes when it comes to analytical fire testing for fabrics. The level of engineering and standardization required is quite impressive.
But it’s critical work because the chemistries and technologies that go into making textiles safer and more fire-resistant have saved countless lives and continue to protect people today.
Alright, that wraps up this episode on flame retardant test methods and standards! I hope you enjoyed it and learned something new. See you next time!
Every year more than 2,000 workers are admitted to hospitals because of burn-injuries, flash-fire accidents, molten metal splash burns, and electric arcs. Reason for these injuries is often lack of proper personal equipment for workers at workplaces. Many of the workers in manufacturing and industrial workplaces don’t wear proper personal protective equipment (PPE) ultimately resulting in workplace accidents. Keeping in mind about workplace casualties, the Regulatory Authorities have made mandatory for companies to provide flame retardant garments to their workers in work environments where the possibility of hazardous incidents is high.
Saving the lives of workers at the workplace should be the first and foremost priority. Now the question is to select the right protective fabric for your workers to keep them safe. When choosing a flame retardant fabric; it’s always important to select that fabric which provides the optimum level of protection by safeguarding against the hazards, particular to the specific workplace. Also, the environment in which the garments made out of flame retardant fabric are to be used should be considered closely so that the fabric not only provides the best protection but at the same time it also fulfills the aesthetic needs.
To help you find the right FR fabric for your needs, consider the following guidelines to be useful:
The very first step in the selection of the suitable flame retardant fabrics is assessing the risks involved in a workplace so that all risks should be discovered. This could be done by hired professionals who carry out a detailed examination of your facility and whom can consider the risk containing factors involved, the extent of damage to be expected against heat and flame in a sudden burst of flash fire, electric arc, molten metal splash or other workplace hazards and the degree of protection required.
One needs to analyze these core factors to make sure the FR workwear you’re buying will provide adequate protection against all of these. It’s the job of the safety professionals and employers to identify all kinds of potential physical or environmental hazards associated with the workplace and against which the workers might be exposed to so that the most appropriate flame retardant garments could be selected for their workers.
When buying flame resistant clothing, your workplace climate acts as one of the most critical factors to consider. A variety of workplace hazards with different intensities and exposure levels always put workers in risky scenarios. The kind of protective garments you choose for your workers to a certain degree will be dependent on whether you work in cold or hot weather conditions. The risk of heat stress or frost damage obviously requires different sort of FR clothing so that the optimum blend of protection and comfort could be attained. So, make sure you predefine your workplace climate before selecting any FR fabric workwear.
Relating to workplace accidents, protective garments have become a compulsory requirement for workers almost in all industries, and every workplace has its own safety standards which specify the type and level of protection that FR garments should provide. Whatever FR clothing you choose, it must live up to your industry certifications and also the local safety standards set forth in the country where the work is taking place.
In order to better understand your industry and workforce requirements, we’ve summarized some of the most commonly used FR related standards as following:
Protective clothing – Clothing to protect against heat and flame. For fabrics’ protection against flame A1, including no melts and drips from the fabric, and against at least one other type of heat, B, C, D, or F. (B-convective heat, C-radiant heat, D-molten aluminum, E-molten Iron, F-contact heat)
Protective clothing for use in welding and allied processes. For fabrics’ protecting against welding, and the critical test factors are: Flame spread, Impact of splatter (of metal), Heat transfer (radiation), Electrical resistance, and Tear, tensile and burst strength.
Standard on flame-resistant garments for protection of industrial personnel against flash fire. For garments that reduce the severity of burn injuries resulting from short-duration exposure to flash fires – how the fabric continues to burn, char length, no melts or drips, as well as heat resistance, and shrinkage at high temperature
NFPA 70E requirements for safe work practices to protect personnel by reducing exposure to major electrical hazards. Originally developed at OSHA’s request, NFPA 70E helps companies and employees avoid workplace injuries and fatalities due to shock, electrocution, arc flash and arc blast.
Standard test method for determining the arc rating of materials for clothing by measuring ATPV and Ebt:
Both ratings can be reported, but the fabric has reached its’ performance max when one of them to test criteria’s have been reached (second degree burn, or break open)
Protective clothing against the thermal hazards of an electric arc. For fabrics’ and garments’ protection from the thermal hazards of an electric arc.
Electrostatic properties – charge decay. Fabrics’ potential or ability to get rid of (dissipate decay charge on its surface) the static electricity charge.
When it comes to FR workwear fabrics, you’ll find plenty of them in the market. There are different types of FR fabrics available depending upon the requirements of various industries. Some of the FR garments are inherently flame retardant while others are chemically treated Breathability of the fabric is a critical factor to be taken into account especially for those working in an environment that presents potential heat stress. Whereas some jobs demand lightweight fabrics, for others durability may be more important. So a blend of different fibers can be used to come up with a product that not only satisfies the protection needs but at the same time also fulfills the aesthetic requirements.
Here are some of the commonly used fibers with their characteristics that serve as raw material to come up with an FR fabric. See which appeals more to your with respect to your workplace requirements.
Each fiber has advantages to bring to FR fabrics if you are guided by expertise in using and blending them. Daletec’s specialists are eager to ensure you find the best fabric for your purpose; our clients tell us this is one of our most helpful and useful services.
Fabric- and garment durability can have very different meanings, but their ultimate focus should be providing better protection to workers, take full advantage of the lifetime of a flame resistant garment and lower the replacement costs. To ensure FR clothing is providing adequate FR protection against hazardous materials & chemicals in the workplace, one must confirm the durability of protective FR garments before making a purchase.
There are a variety of features which can impact the durability of flame resistant fabrics and garments. Some of these include:
What fibers make up the fabric and garment? Blends that incorporate more durable fibers such as nylon and aramids give fabrics more resistance to abrasion, and higher tear strength, providing better and long-lasting durability.
How is the fabric constructed? Every single detail of the fabric construction will affect the durability of the FR fabric and garment. For example, a twill weave may be more durable as compared to a plain weave, the number of threads may have higher tensile strength, but less number of threads may have higher tear strength. The combination of weave, threads, yarn count and weight of fabric all play a role in determining a fabric’s ultimate durability.
The FR performance of apparel is one of the most important factors that should be looked into while selecting from the available options. EN ISO certificates can be achieved after 5 wash cycles but that should not be the limit. The garments have to undergo many more washing cycles throughout their life cycle and the FR performance of the fabric used to make these garments must have durable FR performance so that when washed for multiple dozen times, the protection does not fade away. This is where Daletec takes pride in the way it applies FR performance to its fabrics that are permanent and remains intact throughout the life time of the garment, as long as prescribed washing instructions are followed.
How is the garment assembled? As with the fabric, garment construction details like garment design, seam type, fit, trims and features can make a contribution to durability, but no single attribute should be selected as the determining factor for durability.
It’s important to make sure you follow the proper instructions for the flame retardant fabrics which you’re buying. Proper care must be taken while washing them. For instance, washing them with regular chlorine bleach will affect their protective properties and may result in reducing or even removing FR properties. All detergents sold for home use can be used except for ones containing hydrogen peroxide, sulfuric acid and other chlorine-containing chemicals that will not only affect the FR performance but also will result into challenges like drastic color change.
Usually, it is recommended to launder FR fabrics at dedicated laundry facilities but most flame-resistant garments can be handled safely using common laundering and care procedures. Remember, FR clothing is safety apparel that just might save your life. To keep your flame-resistant garments in excellent shape, it is important that the prescribed washing temperature, drying procedure and other care instructions by the fabric supplier must be followed. Similarly, as far as repairing of flame retardant apparel is concerned, specially treated thread and fabric patches must be used while keeping in mind that safety requirements aren’t compromised.
Still, there are some safety measures that need to be followed to ensure your FR garments maintain their maximum effectiveness.
These days, you’ll find flame retardant fabrics everywhere. Garments made out of these are used to provide protection in different sectors of everyday life. And honestly they’re doing pretty well, but the majority of them are encountering a similar problem; “washout”. Regular spot tests show that many flame retardant (FR) fabrics burn after only a few washes. Garments made out of these are the last line of defense, so it is really important that the credibility on the FR performance of the fabric is never compromised. Never choose an FR garment that may burn after a few washes. Always select those protective fabrics which can document FR certifications and guarantees to remain flame resistant throughout the lifetime of the garment, because that’s what you’ll be looking for.
If your workers like the way their FR clothing looks and fits, they are more likely to wear it. Fortunately, FR clothing manufacturers have made significant improvements in style over the number of years by coming up with designs that are more appealing and still meet the relevant safety standards. These days’ people are also inclined towards looks and fashion along with protection, therefore FR product lines have been updated to provide newer and trendy FR garments. One of the most recent FR innovations is improved FR clothing design with a more casual and comfortable feel. As we say confidence is often linked to feel good in your own skin, but a nicely designed FR workwear can often do the job too. A variety of new inspiring FR garments are now available. So, when buying flame retardant garments, whether inherently or chemically treated, remember to choose the one that’s trendy.
Being uncomfortable can put your workers and workplace both at risk. When your FR garments are not comfortable, the workers will be more likely to take shortcuts ultimately resulting in workplace accidents. By choosing the right flame resistant garments, your workers will be more likely to wear them. This will not only increase compliance to FR safety regulations, but it will also increase productivity, reduce the chances of workplace hazards and improve workers morale. Lastly, there are some FR fabrics in the market which rough hand feels, ultimately resulting in irritation over the skin when applied in direct contact with. As a result, skin safety along with comfort has rapidly become a key factor in a wearer’s purchasing decision. Make sure you buy those FR garments which can be worn comfortably against the skin without causing any irritation or problem. Therefore, keep all of these attributes in mind before making a purchase.
Quality never happens in a day. It takes months, years and even decades to establish oneself as a quality manufacturer. Similarly, a manufacturer’s credibility is dependent on the safety of its products along with the level of trust of its customers. Nowadays, you see so many FR fabric players in the market claiming top-notch FR protection, but when you take a closer look at their quality and level of protection against various workplace hazards; you’ll be surprised and think twice about the claims they’re making.
Remember, a credible FR fabric manufacturer never compromises on two things; safety and consistency of its FR fabric. As a matter of fact, a low-quality FR workwear mostly leads to serious fatal injuries or workplace causalities. Therefore, make sure you buy from a reputable FR fabric manufacturer and always pay for a good quality FR fabric because it’s gonna pay off in the long run.
Make sure to use these simple guidelines for selecting your flame retardant fabrics wisely.
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