Even the most comprehensive safety program can only mitigate—not eliminate—risk associated with the flash fire hazard. A reliable and controllable means of protecting employees from harm is the proper use of PPE. In a flash fire context, flame resistant clothing provides further protection and offers a foundational defense. This paper guides safety managers and purchasers in the selection, use, care and maintenance of clothing for flash fire protection that’s compliant with the industry consensus standard NFPA® 2112.
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Arming your crew with the appropriate FR gear is a feat in itself. Navigating the ever-changing sea of standards? Now that’s another beast entirely. Bulwark is here to help you choose the right FR program by ensuring you have a thorough grasp on the standards and what they mean for you—and your crew.
When the National Fire Protection Association (NFPA) introduced the term “Arc-Rated” or “AR” in its 2012 revision to NFPA 70E, it was a bit of a head-scratcher. The question on every safety manager’s mind was: what’s the difference between FR and AR? According to Bulwark’s Technical Training Manager, Derek Sang, the most basic and important thing to know when it comes to FR and AR is that all arc-rated clothing is flame resistant, but not all flame resistant clothing is arc-rated.
For a piece of clothing to be considered flame resistant, the fabric used to make the garment must withstand ignition and/or rapidly self-extinguish in order to protect the wearer from the dangers of flash fire, arc flash, molten metals and other hazards. In the event of a flash fire or arc flash, the FR PPE worn must resist catching fire, melting, and continuing to burn after the initial flash to act as a barrier between the wearer and the hazard.
The fabric used to create arc-rated clothing is subject to additional tests, above and beyond fabric labeled simply “FR.” Primarily, it is exposed to a series of arc flashes to determine how much energy the fabric is able to block before it would likely cause the wearer to obtain a 2nd degree burn, 50% of the time. The result of this test, expressed in calories, is known as the Arc Thermal Performance Value (ATPV).
Current standards for arc flash protection, detailed by NFPA 70E, state that all PPE clothing must also be flame resistant to qualify for an arc rating. In other words: all AR clothing is FR, but not all FR clothing is AR. This is because, based on the results of the series of tests outlined above, equipment rated FR may not always provide the adequate level of protection for workers who are at risk of encountering arc flashes. These employees—general industry electricians (70E)— must wear the appropriate level of AR clothing for the hazard, in order to reduce their risk of serious injury or death caused by an arc flash.
OXNARD, Calif. (Feb. 19, 2018) — From fires and explosions to sharp objects, pathogens and dangerous chemicals, laboratories are home to a variety of hazards. To help promote lab safety, Workrite Uniform Company — a manufacturer of protective workwear, including lab coats — recommends following these safety tips.
1. ESTABLISH A COMPREHENSIVE SAFETY PROGRAM
Based on the hazards in your laboratory and the applicable safety standards and regulations, determine the equipment, procedures, emergency protocols and environmental conditions that will best facilitate safety. Be sure to document the program and complete ongoing audits as needed.
2. CREATE A CULTURE OF SAFETY
Once you’ve established a safety program, it is important to communicate all safety information clearly and ensure laboratory personnel and visitors fully understand the actions they need to take. Make sure that safety is treated as a top priority and that each individual has the safety resources they need and feels comfortable bringing up safety concerns.
3. FOLLOW SAFE WORK PRACTICES
Outlining safety procedures is one thing — following them consistently is another. Even basics such as keeping food out of the lab, storing chemicals correctly, practicing good housekeeping in work areas and washing your hands can easily be forgotten. Remember that skipping a step even once can have devastating consequences.
4. USE THE PROPER PPE
Personal protective equipment (PPE) can include lab coats, safety glasses or goggles, gloves, and beyond. Always ensure that the equipment you select is designed for the hazards present in your laboratory. For example, you may need lab coats that are flame-resistant (FR), offer chemical-splash protection (CP) or provide a combination of both (FR/CP).
5. REGULARLY RE-EVALUATE YOUR APPROACH
Even if you have a strong safety program in place and have gone awhile without an accident, it is still important to be vigilant. Stay on the lookout for potential safety issues as well as new innovations in laboratory safety, and continue to improve your program over time.
Workrite Uniform manufactures chemical-splash protection (CP) lab coats, flame-resistant (FR) lab coats and FR/CP lab coats that combine thermal and chemical-splash protection in a single garment.
Depending on the line of work you’re in, there are any number of dangers you may encounter on the job. From slip-and-fall hazards to those due to working at height, there’s PPE to help keep you protected. When it comes to thermal hazards, your FR clothing protects you against two main hazards: Flash Fire and Arc Flash.
A flash fire is a rapid moving flame front that can be caused by a diffuse fuel, such as dust, gas, or the vapors of an ignitable liquid, without the production of damaging pressure. In the Oil & Gas industry, which includes exploration, drilling, field services and refining, flash fires are the primary hazard FR protects against.
NFPA® 2112 and NFPA® 2113 are the “go-to” industry consensus standards that address flash fire. Once safety managers have identified they have a flash fire hazard, FR is necessary. Selecting the appropriate FR garments for your safety program should be based on a number of factors such as protection, comfort and durability.
An arc flash is a powerful and dangerous occurrence where an electric current leaves its anticipated path and travels from phase to phase, or phase to ground. The resulting explosion produces extremely high temperatures, acoustic energy and concussive force. When a person is in close proximity to the arc flash, serious burn injury and even death can occur.
The Arc Flash hazard affects all who work in and around energized electrical equipment. This can include general industry electricians, maintenance workers and operators, as well as our electric utilities, including transmission, distribution, generation and metering. As employers, it is your responsibility to ensure that all employees exposed to the hazard are protected with arc-rated flame-resistant clothing.
No matter which hazard your FR clothing is designed to address, the success of any program is dependent upon the proper selection, use, care and maintenance of your FR program. For more information on how to select the right FR for your needs and tips on implementing a FR clothing program, get in touch with a Bulwark FR expert.
Laboratory workers are often exposed to an abundance of flammable and combustible liquids that pose the risk of burn injury. Employers that implement a PPE program that’s specific to lab hazards will help protect workers and labs from the outcomes of serious injuries from exposure to these hazards. This whitepaper provides employers with information on the uses and benefits of FR/CP and CP lab coats.
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AR, FR, ATPV, OSHA. The list goes on and on. If there’s one thing that’s true about FR safety, it’s that there are a lot of terms to memorize. It’s not always easy to keep the various words and acronyms straight, but when it comes to building and implementing an effective safety program, knowing your FR vocabulary is important. Here, our FR experts have compiled the most important of those terms in a handy alphabetized glossary so you can create a culture of compliance.
An arc flash is a type of electrical explosion where temperatures can reach or exceed 35,000 °F. The Arc Flash hazard affects all who work in and around energized electrical equipment. This can include general industry electricians, maintenance workers and operators, as well as our electric utilities, including transmission, distribution, generation and metering.
Arc-Rated (AR) Protective Clothing
Arc-rated protective clothing protects from arc flash and electric arc hazards. AR garments are measured in cal/cm². The total AR clothing system must meet or exceed required arc protection levels. Remember, all AR is FR, but not all FR is AR.
Breakopen is the formation of holes in the fabric during arc rating testing. This is the point of failure of FR protective garments.
Energy Break-Open Threshold is an alternative measure to ATPV when that measure cannot be used due to breakopen.
A rapid moving flame front that can be caused by a diffuse fuel, such as dust, gas, or the vapors of an ignitable liquid, without the production of damaging pressure. Flash fire is the primary hazard in the Oil & Gas industry, which includes exploration, drilling, field services and refining.
Hazard Risk Assessment
The first step in the creation of any PPE program is the Hazard Assessment. Federal regulations require employers to assess the workplace to determine if hazards that require the use of personal protective equipment are present or are likely to be present. These include impacts, combustible dust, fire/heat, and chemical hazards, among others.
HRC (Hazard Risk Category)
Hazard risk categories are defined by NFPA® 70E and assigned based on risk associated with electrical safety and arc flash. HRC levels determine the appropriate ATPV of flame-resistant clothing for a given task.
Replaces HRC in 2015 edition of NFPA 70E, the “0” category was eliminated in NFPA 70E 2015. The minimum ATPV’s for PPE Category 1 through 4 are the same as they were for HRC, and the new PPE table only specifies PPE for work within the arc flash boundary.
HRC 2 rated garments have an arc rating between 8 cal/cm² and 25 cal/cm² and are often referred to as “daily wear.”
HRC 3 rated garments have an arc rating between 25 cal/cm² and 40 cal/cm².
HRC 4 rated garments have an arc rating equal or greater than 40 cal/cm². These high ratings are achieved with a layered FR system. Download our FR Layering Fact Sheet to learn the do’s and don’ts of layering for FR.
Inherently Flame Resistant
Inherently flame resistant fabrics are engineered to be flame-resistant at the fiber level, and do not require any additional finishing.
The National Fire Protection Association is an agency whose task it is to promote and improve fire protection and prevention. They publish National Fire Codes.
Refers to NFPA’s “Standard on Flame Resistant Garments for Protection of Industrial Personnel Against Flash Fire.” NFPA® 2112 is the “go-to” industry consensus standard that addresses flash fire. It defines the testing methods and performance requirements for flame-resistant fabrics for this hazard.
The “Standard for Electrical Safety in the Workplace,” NFPA® 70E is meant to protect those working around potential arc flash hazards. Note that NFPA® 70E applies only to general industry electrical safety, not to electric utility workers.
Founded by the Occupational Safety & Health Act of 1970, The Occupational Safety and Health Administration’s (OSHA) mission is to “assure safe and healthful working conditions for working men and women by setting and enforcing standards and by providing training, outreach, education and assistance.” Their general duty clause ensures a safe workplace for all employees and is the basis for all industry consensus standards. OSHA determines regulations and standards related to personal protective equipment.
The regulation states that power utilities make reasonable estimates of the incident heat energy to which their employee would be exposed, and that employees exposed to hazards from electric arcs wear AR clothing and other protective equipment with an arc rating greater than or equal to the estimated heat energy.
Founded in 1918, The American National Standards Institute coordinates and develops voluntary standards for products, services, and systems. The organization’s goals include performance consistency and product safety. It is the U.S. member body to ISO and IEC.
PPE (Personal Protective Equipment)
Personal protective equipment is specialized safety gear worn by an employee for protection against a hazard. Flame resistant/arc rated garments are a form of personal protective clothing worn against thermal hazards.
Moisture wicking fabrics pull moisture (sweat) away from the body and dry quickly, keeping the wearer cooler, dryer, and more comfortable. Bulwark iQ Series® FR Comfort Knits and Wovens are among the best moisture wicking FR garments available.
Breathability refers to how well a fabric allows air to be transmitted through the material. The more air that passes through, the cooler the wearer stays. Bulwark iQ Series® Endurance Collection is the first of its kind to offer high level FR protection in a material that is extremely breathable and durable.
NFPA® 2112 is the well-known and often quoted safety standard to those who work in the Oil & Gas Industry — no matter where they fall in the stream. And while 2112 is an important standard on how to specify the minimum performance requirements and test methods for flame-resistant fabrics and components, it does not provide any guidance for the selection, use, care, and maintenance of FR clothing. NFPA® 2113 is your go-to safety standard in regard to building your FR clothing program.
NFPA® 2113 walks safety professionals through their hazard assessment, explains how to specify clothing based on the requirements of NFPA® 2112. NFPA 2113 is where you will find proper care and maintenance addressed. NFPA® 2112 lays out the minimum performance requirements and test methods that FR garments must meet in order to enter the market, while NFPA® 2113 focuses on minimizing the health and safety risks by choosing the correct garment based on the proper selection criteria and how to properly wear FR garments in the field.
In addition to proper care and maintenance, NFPA 2113 stipulates the training guidelines that help ensure your program is in compliance with OSHA 1910.132, the often cited regulation when FR clothing programs fail to meet OSHA requirements.
Even though NFPA 2112 may get all the headlines and recognition as a safety professional NFPA 2113 is your go-to standard.
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There’s a lot of confusion when it comes to the terms “treated” and “inherent” FR. What’s the difference? And, more importantly, does one offer better protection than the other? In short, the answer is no. But in order to understand why, we must start by understanding what these terms mean and why they were applied to FR fabric in the first place.
Definition & Engineering
“Inherent” FR refers to a fabric that has FR properties—defined by the fabric’s ability to self-extinguish when the ignition source is removed—by its very nature, as a core property. In other words, a fabric is FR without any additional finishing. “Treated” FR on the other hand, refers to a fabric that has been engineered with flame-retardant chemistry to have FR properties that were not present prior to the treatment.
There are 3 levels at which FR properties can be achieved:
• The Molecular Level – Synthetic derivatives are engineered at the molecular level to be FR (e.g., Nomex, Kermel, Twaron, Kevlar, etc.)
• The Fiber Level – At this level, flame-retardant chemicals are added to the process prior to the fiber being extruded (e.g., FR Modacrylics, FR Rayons)
• The Fabric Level – FR properties are permanently imparted into flammable fabrics through a combination of chemical and mechanical processes (e.g., FR Cotton, 88/12)
When these terms were adopted by the FR world over 30 years ago, they reflected the durability of flame resistant technology at that time. Back then, the intent was to imply that “Inherent” was superior to “treated.” Why? Because at one time, it was true. Cotton and other cellulosic materials are naturally flammable, so they do have to undergo a chemical process, or “treatment,” to impart FR properties. And these early “treated” garments did lose their FR properties over time and after repeated washings. Treated fabrics, prior to 1987, could not compete with aramids as a durable FR alternative.
Over the past 30 years, however, we’ve made dramatic advancements in FR technology that have blurred the lines between these two terms. “Inherent” and “treated” have become so common and so misused that the terms now create more confusion than clarity. Most popular FR fabrics today are blends of several different fibers, and this has created confusion on where and when to apply the current labels. Because “inherent” and “treated” refer to single fiber types, they fail to accurately represent today’s complex blends—which sometimes combine all 3 engineering levels. For example, what should we call a fabric that is 35% Aramid (engineered at the molecular level) and 65% FR cotton (engineered at the fiber level)? When a fabric is a combination of both inherent and treated FR fabrics, and with no rules in place about how to apply the terms, they become more confusing than helpful.
FR technology has come a long way. The fabrics in use today are far superior to those of just a generation previous, and the terms we use to discuss them must make the same evolution. The bottom line is, when it comes to selecting FR fabrics, the most important considerations should always be protection, comfort and durability. No matter which fabric you select, be sure that you can count on the FR properties to last, wash after wash. Bulwark offers an FR guarantee for the lifetime of the garment, on all of our products. To ensure your safety program does what it’s supposed to do: keep you and your guys safe.
When you think about establishing a successful FR clothing program, what “check list” items immediately spring to mind? Generally speaking, the first two mental steps people in this industry take are: 1.) Evaluating the thermal hazard you are providing protection for; and 2.) Selecting the appropriate FR garments for that hazard.
But for your FR program to be fully effective, you need to look beyond just choosing the right gear for the environment you and your crew are working in. You need to examine every layer closely, beginning with your base layers.
Fact is, an FR clothing program is not fully defined if it does not place restrictions or set guidelines on clothing to be worn under the FR uniform. In the worst circumstances, lack of guidance on base layer clothing can leave an employee at risk for injuries. Consider, for a moment, the extent of an injury that could be sustained by someone wearing a t-shirt made of synthetic fibers under their FR clothing. Sure, the outermost FR layer will self-extinguish in a thermal event. But enough thermal energy could transfer to the t-shirt underneath, causing it to melt to the wearer’s skin.
One simple way to manage this issue is to mandate that all undergarments be made of 100% cotton or other natural fiber. However, this option places the responsibility of choosing compliant clothing squarely on the employee. And, it will require additional “policing” on your behalf.
In our opinion, the most comprehensive approach is for the employer to specify and issue the appropriate FR base layers to be worn under the company’s FR uniforms. By doing so, not only are you taking the choice of undergarments out of the hands of your employees, and the questions of whether or not they have the right fiber content against their skin out of the equation. You will also be providing a second layer of FR protection should they inadvertently leave a shirt unbuttoned or untucked in a moment of complacency. (A layer that, believe it or not, can also provide greater comfort; most FR undergarments pull sweat away from the body to help keep workers cool and dry.)
In the case of protection against electric arc exposure, only FR layers can contribute to a composite ATPV rating, so issuing an FR base layer to be worn under an FR shirt may increase ATPV and possibly increase protection.
So, there you have it. Your base layer basics, compliments of the world’s #1 FR brand. Next time you’re evaluating your FR program, please keep these tips top of mind. And don’t let your undergarments become an oversight.
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ABOUT GEORGE George Harmer is the Safety Director for General Production Service (GPS) where he’s been for the last 13 years. He has spent over 25 years in the oil and gas industry starting out at an entry level position and ultimately working into safety and risk management. Currently George oversees a team of 15 safety professionals responsible to over 500 employees. Utilizing a variety of innovative solutions GPS is recognized as a “world-class” organization with their business partners.
Recently, George sat down for a Zoom chat with his longtime friend and Bulwark Business Development Manager, Rick Fisher. They talked about being a Safety Manager, what it means to be in charge of other people’s safety, and how Bulwark helps empower GPS to protect their employees. Watch the full interview above, or check out the highlights below.
RF: Tell me what a given day looks like for a safety director at GPS? GH: No day is the same in our business. You know, we have a lot of challenges that could arise every day. So typically you get to the yard, you know, 5:30 in the morning, uh, greet what guys I can see. I like to get here early to greet the workforce. And I feel that greeting the workforce every day shows them that we care. So greeting the workforce, and then I get phone calls all the way up until the last crew comes home every day.
RF: Does it put a strain on your family, George, being in such a tough business [the oil and gas business]? GH: Um, yeah, I mean, there's a lot of uncertainties, you know, every day that we wake up and go into this field. There's, you know, uncertainty with new regulations that may be coming in on the environmental side, on the health and safety side. So it's always difficult with that uncertainty and then too, the other caveat to this job is being able to go home. You know, your spouse sometimes wants to know how your day went. There are so many things that I deal with on a confidential level, protecting employees. Sometimes that makes it tough, you know, because your spouse wants to talk about your day and you don't have that ability. So that definitely makes it tough. Not having the option to vent, I guess if you would.
RF: So as a safety manager or safety professional, what is the toughest part of your job? GH: The toughest for sure, part of my job, is having to make that phone call to a family member that someone was hurt. I take it personal. I don't allow any of my other staff to make those phone calls. If somebody didn't go home safe today, I make sure that I call that spouse or family member. Just recently it wasn't even related to General Production’s work. We had an employee commuting to work, and unfortunately he didn't make it to work that day. He was killed in a car accident. The regular, you know, CHPs and some of the other folks that should've made that call took too long, and I couldn't stand by and have a spouse and a son and a daughter wonder where their father is. So I had to go out there and let them know that he was gone. So, you know, I take that very personal, whether they're on the job or this happens off the job, you know, we love our employees and I want to make sure they're taken care of.
RF: Yeah, I'm sorry that you would have to go through that or anybody in your company or their families. Switching gears. George, what is the best part about your job being a safety professional at General Production Service? GH: Hands down the best part is going out there and [knowing that] the employees know that we care about them. Every year General Production Service has an annual company picnic. Meeting the families, you know, seeing the kids playing out there and having all the families come up to me during that time and say how much they love this company, because of the company loves them. So that's by far the greatest, just intermingling with family members and the company and letting them know how much I care about them.
RF: So I know that safety is a huge part of your job task. Tell me a little bit about your flame resistant apparel program. GH: We started this program, I want to say back in 2011-ish or 12, that's where we first met. When we started this process, it's been something that's challenging at times. And the reason I say challenging is if you're not hooked up with the right person to help you through this process, you'll be in garments that don't fit the needs to the employees. Like, they're not comfortable. So it was challenging for the first a year and a half before you and I met and we sat down and that's the one thing that I found that helped us out the most is when you came in and sat down with us, it was different. And I say different because you didn't come in and say, this is what you need. You came in and said, what do you need? So for me, that took the challenge out of it.
RF: So when you chose Bulwark as your protective apparel brand, give me some of the most important factors, like environmental heat, comfort. Tell me the things that really mattered most to George Harmer. GH: Well, the first thing definitely was comfort because if the guys don't—if they're not comfortable—they're not going to wear them properly, or they're not going to wear them at all. The other thing was, you know, we live in California in the Central Valley. Our summers can get unbearable to most folks, you know, just last week we had temperatures up to 109° in areas. So these guys gotta be able to…1. I have to comply with the FR regs. And then 2. I also have to make sure that our guys go home every day. And we comply with the heat on this prevention program that is set forth by Cal OSHA. So they have to be lightweight and breathable for the employees.
RF: So comfort was extremely important to you. Heat stress, having a garment that could breathe and cool the body. And if I remember correctly, you guys were having issues with your older product prior to Bulwark, not withstanding the rigorous strengths of what you guys do. Can you tell me a little bit about that? GH: Yeah. Durability was a factor in the early times of our FR program. They wouldn't hold up to what we're doing out in the field. When I say we are a heavy wear company—it was amazing when we started working with Bulwark—When I said heavy wear, you brought a team out here and said, show us. No other company [did that]. They all said, “Oh, we understand heavy wear. We have a lot of heavy wear contracts out there.” They didn't have a clue. In well servicing, you're touching metal all day long. We're in high soiled conditions every single day. So these folks early on had to go at these garments so tough [with] high temperatures to wash on, chemicals to get the hydrocarbons out of the uniforms. So it was just destroying the fabric. So that's why we, when you came out, you not only said to us, what do you need? How can we help? You said, what can we produce for you? So working together, I think, came up with one of the best garments and fabrics that's on the market right now, the iQ series®.
RF: What makes you nervous about not only just your FR program, but your [overall] safety program, when you wake up in the morning and think about safety, George? GH: You know, every day, uh, I go to bed thinking about it and I wake up thinking about it. The first thing I think about is, [is] today the day that someone's not going to do the right thing? You know, we have some mottos around here, it's our brother's keeper. So we want to empower each employee to take care of one another. We tell them, 1. you have an obligation to yourself. [2.] You have an obligation to that guy that's working next to you and an obligation to their family to make sure that they go home safe every day. So you just think, is today the day that someone's not gonna take a stand for safety. So that's why I coach my guys every day to make sure they're out there, coaching those employees to do the right thing. So that's what you worry about every day. And if you don't, you're in the wrong field, you should not be in the safety profession. If you don't think about that every day, and think about the employee's wellbeing, this is the wrong job for you.
RF: It must be a heavy burden. And I appreciate the candor. So you have the right tools. You have the right product. Tell me a little bit about the training that you give your employees on the flame resistant apparel. GH: You know, every year we have an annual core training that we bring our employees in to go over our core values. Those are safety values. Those are corporate values. Those are our customer values. So to bring them in for that, and then to show them how to care for the garment out in the field. Thankfully our folks right now don't have to launder them themselves. We actually use a third party to launder our garments, but we do have some supervisors. And now we're taking that next step to give some of our folks the ability to care for their garments themselves. So really just to show them what the garment can do, you know, what it's intended to do. Some folks that we see out in the field—they don't work for our company—they'll have their garments untucked. So our guys will actually tell them, “Hey, you know, the whole purpose of that garment is to protect you in the event of a flash fire. And if you have it untucked, it's not doing what it's designed to do.” So just the training that we give our folks, they're able to go out and express that to other contractors that may be working in the area. So it's an empowering thing.
RF:That's really great to hear. Has Bulwark helped you guys understand the training process behind the flame resistant apparel? GH:I will say that's an absolute, yes. And it's—I can tell the folks that may be watching this, um, Bulwark folks have been on our property over the last, let's just say nine years, more than a hundred times. That's you coming out, dealing with our folks, going out in the field with us, bringing your research team down here to look at what we're doing. So, absolutely. Bulwark has been not only a help in developing the perfect garment for us, but coming out and showing our employees how much they care about them to produce a garment that would protect them, train the employees. So it's been a wonderful partnership.