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Use and Maintenance of Flame-Resistant (FR) High-Visibility Coveralls
1. Purpose and Scope
This Standard Operating Procedure (SOP) outlines the mandatory requirements for the wear, inspection, and maintenance of High-Visibility FR coveralls. On this job site, your coveralls are your final line of defense against flash fires and arc flash incidents. Failure to follow these guidelines could result in catastrophic, life-altering injuries.
2. The Critical Hazard: Layering and the “Melting” Risk
It is a common—and potentially fatal—misconception that FR coveralls provide a “shield” that allows you to wear whatever you want underneath.
Never wear non-FR synthetic materials (such as polyester, nylon, or spandex) under your FR coveralls. In the event of a thermal incident, FR fabric is designed to char and self-extinguish. However, heat transfers through the fabric almost instantaneously. If you are wearing synthetic “dry-fit” shirts or nylon gym shorts underneath:
- The Melting Point: These synthetics will melt at temperatures far lower than the flame itself.
- The “Second Skin” Effect: The plastic will liquefy and fuse directly to your skin, causing severe 3rd-degree burns that are incredibly difficult for medical professionals to treat.
- Approved Undergarments: Only 100% cotton, silk, wool, or specialized FR-rated base layers are permitted.
3. Proper Wear and Fit
For your gear to function, it must be worn as designed:
- Fully Zipped: Coveralls must be zipped to the top. An open collar exposes the chest and neck to thermal energy.
- Cuffs Secured: Sleeves must be rolled down and cinched at the wrist.
- Fit: Ensure your coveralls are not excessively baggy (snag hazard) or too tight (breaks the protective air gap between the fabric and skin).
4. Daily Inspection Checklist
Before every shift, perform a “Circle Check” of your garment. If your coveralls fail any of the following points, tag them out and request a replacement immediately.
| Inspection Point | What to Look For | Why it Matters |
| Oil/Grease Saturation | Visible dark spots or “slick” feeling on the fabric. | Hydrocarbons are flammable. A grease-soaked FR suit becomes a torch. |
| Reflective Tape | Fraying, peeling, or “graying out” (loss of retro-reflectivity). | If the tape fails, you are invisible to heavy equipment operators. |
| Holes & Tears | Any gap larger than a dime, or frayed seams. | Heat will enter the “window” and burn you instantly. |
| Cleanliness | Presence of combustible dust, paint, or solvents. | Contaminants can ignite on the surface of the FR treated fibers. |
| Closures | Broken zippers, missing buttons, or non-functional Velcro. | Garments must remain closed to maintain a thermal seal. |
5. Maintenance and Laundering
- No Bleach: Never use chlorine bleach or fabric softeners. These chemicals strip the FR treatment from the fibers and coat them in flammable waxes.
- Heavy Soiling: If coveralls become saturated with fuel or hydraulic fluid, they are compromised. Do not attempt to wash them at home; notify your supervisor for professional decontamination or disposal.
Your safety is non-negotiable. If your gear is compromised, you are compromised.
