When it comes to protecting yourself on the job, flame-resistant (FR) outerwear gets a lot of attention—but what you wear underneath is just as important. Base layers can mean the difference between walking away safely or suffering serious burns during an arc flash or flash fire. But is 100% cotton enough, or do you really need FR base layers?
Let’s break it down.
Why base layers matter
In hazardous work environments like oil & gas, electrical utilities, manufacturing, and construction, exposure to heat, flames, and arc flashes is a daily risk. While your FR shirt and pants offer critical protection, your base layer plays a major role in reducing burn severity.
Why? Because during an incident, non-FR layers can ignite, melt, or contribute to injury—even under an FR outer layer. Choosing the wrong base layer can defeat the purpose of your protective gear.
Myth: “100% cotton is safe enough”
This is a common misconception. Cotton doesn’t melt like synthetic fabrics, but it will still ignite and burn, often sticking to the skin. Once ignited, it can fuel a fire under your FR clothing—turning a survivable event into a life-altering injury.
In fact, OSHA and NFPA 70E both warn against wearing flammable materials under FR gear, including cotton, polyester, or blends.
What are FR base layers?
FR base layers are made from specially treated or inherently flame-resistant fabrics designed to:
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Self-extinguish when exposed to flame
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Not melt or drip
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Reduce body burn percentage during thermal events
They’re also designed for comfort, offering moisture-wicking, breathable performance that helps you stay cool on the job.
Cotton vs. FR base layers
|
Feature |
100% Cotton |
FR Base layer |
|
Flame resistance |
No |
Yes |
|
Melting hazard |
Low (burns instead) |
None |
|
Meets NFPA 70E / OSHA |
No |
Yes |
|
Contributes to burn |
Yes |
No |
|
Comfort |
Moderate |
High (moisture-wicking) |
When do you need FR base layers?
If you're in any of these environments, FR base layers aren't optional—they're essential:
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Electrical work with arc flash potential
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Oil & gas drilling, refining, or fracking
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Chemical manufacturing or processing
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Utilities & industrial maintenance
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Any NFPA 70E or OSHA-compliant jobsite
Top FR base layer picks from Novarlo
To help you choose the right gear, here are some top-rated FR base layer options available at Novarlo:
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Drifire FR lightweight knit long John Pant base layer: These pants are inherently flame-resistant, ensuring protection won't wash out. They feature breathable fabric and moisture-wicking technology to keep you dry and comfortable.
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FR/arc flash resistant long sleeve mock turtleneck- 2 shirts: This mock turtleneck offers an arc rating of 12 cal/cm² and is compliant with NFPA 70E standards. Its lightweight, moisture-wicking fabric ensures comfort during extended wear.
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DRIFIRE thermal long sleeve T-Shirt fire (FR) and Arc flash resistant: Designed for layering, this long sleeve t-shirt provides breathable fabric and moisture-wicking technology to keep you dry. It's inherently flame-resistant, ensuring long-term protection.
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Long underwear bottom Fire (FR) and Arc flash resistant: With an arc rating of 15 cal/cm², these bottoms offer exceptional protection. They're made from lightweight, moisture-wicking fabric, ensuring comfort without compromising safety.
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Hi Vis FR t-shirt CAT 1 Arc flash, short sleeve: This high-visibility t-shirt is inherently flame-resistant and features moisture-wicking technology. It's an excellent base layer choice for staying protected in various environments.
OSHA & NFPA 70E compliance
Understanding the regulations is crucial for workplace safety:
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OSHA 1910.269: This standard covers the operation and maintenance of electric power generation, transmission, and distribution lines and equipment. It emphasizes the need for protective clothing that does not ignite or melt.
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NFPA 70E: This standard provides guidelines for electrical safety in the workplace, including the requirement for FR clothing that minimizes the extent of injuries.
Don’t gamble with layers
While 100% cotton might seem like a “better-than-polyester” option, it still puts you at risk. FR base layers are designed to work with your outer FR gear to create a full system of protection—keeping you safer in the worst-case scenario.
At Novarlo, we stock top-tier FR base layers that meet industry standards while keeping you cool, dry, and compliant. Because real safety starts at the base.