PPE/Specific/TBT-PPE-031

Flame Retardant Overalls

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Flame Retardant Overalls

Toolbox Talk Record

Ref: TBT-PPE-031  |  Issue: 1  |  Date: April 2026
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What?

  • Flame retardant (FR) overalls are specialist workwear designed to resist ignition and limit burn injuries.
  • FR clothing is required for hot works, ATEX zones, arc flash risk areas, and work near flammable materials.
  • Standard cotton or polyester workwear can ignite, melt, and fuse to skin, causing severe deep burns.
  • FR overalls are rated to EN ISO 11612 for heat and flame, and EN 1149 for anti-static properties.
  • Arc flash rated clothing carries an ATPV rating measured in calories per square centimetre for electrical risk.
  • FR properties can degrade over time through washing, contamination with flammable substances, and physical wear.
  • DSEAR 2002 requires anti-static FR clothing in ATEX classified zones to prevent static spark ignition.
  • FR overalls must be worn fully fastened with sleeves rolled down and no gaps at the neck or cuffs.
  • Synthetic base layers worn under FR overalls can melt and cause burns even if the outer garment performs correctly.
  • The employer must provide FR clothing where the risk assessment identifies fire or flash hazard exposure.

Why?

Prevent burn injuriesStandard clothing ignites and continues burning — FR overalls self-extinguish, giving critical seconds to escape the flame source.
Arc flash protectionElectrical arc flash reaches temperatures of 20,000°C — only rated FR clothing provides any survival protection at all.
ATEX complianceAnti-static FR clothing prevents static discharge that could ignite explosive atmospheres in classified ATEX zones.
Do Don't
  • Wear FR overalls for all hot works, ATEX zone entry, and arc flash risk activities.
  • Check the garment label confirms the correct EN standard rating for the identified hazard.
  • Fasten all buttons, zips, and cuffs fully before entering the hazard area.
  • Wear natural fibre base layers such as cotton underneath FR overalls at all times.
  • Inspect FR clothing before each use for damage, holes, and heavy contamination.
  • Follow the manufacturer's washing instructions to maintain FR performance over time.
  • Replace FR overalls that are torn, heavily stained with oil, or past their service life.
  • Store FR clothing separately from standard workwear to prevent mix-ups on site.
  • Ensure FR overalls fit correctly — too tight restricts movement, too loose catches snags.
  • Report any flash or flame contact incident even if the garment appears undamaged.
  • DON'T wear standard polyester or nylon clothing for hot works or ATEX zone tasks.
  • DON'T wear synthetic base layers under FR overalls — they melt onto skin in a flash.
  • DON'T roll up sleeves or leave the coverall unfastened when entering hazard areas.
  • DON'T use FR overalls contaminated with oil, grease, or flammable substances.
  • DON'T wash FR clothing with fabric softener — it degrades the flame retardant treatment.
  • DON'T iron FR overalls at high temperatures that could damage the protective finish.
  • DON'T repair FR clothing with non-FR patches or stitching — the repair becomes a weak point.
  • DON'T assume all FR overalls provide the same protection level — check the rating.
  • DON'T continue wearing FR garments that have been exposed to a fire or arc flash event.
  • DON'T store FR clothing near heat sources, chemicals, or in direct sunlight long-term.

See also: Hot Works Permit Requirements | ATEX Zoning
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