Introduction: What is flame retardant fabric?
To some extent, flame-retardant fabric means any type of fabric that does not catch fire easily, prevents the spread of fire, or can put itself out. These types of fabric are best for places that deal with dangerous fire threats.
Unlike other types of fabric that can easily catch fire, flame-retardant fabric acts as a barrier so that the wearer does not get burned, and the fire does not get fueled by other burning materials. The type of burning material and how the clothes are constructed will determine how fire-retardant the fabrics can be.
These flame retardant fabrics are produced by two main methods. One method uses flame-resistant fibres, which are pre-designed with a molecular chemistry that does not burn easily. The other method treats fabrics with finishing chemicals designed to create a barrier to fire. Both of these methods go on to serve different industries such as oil and gas, electrical utilities, emergency response, aviation, and commercial furniture.
These fabrics must pass fire safety standards and testing to be sold. Some of these standards are NFPA 2112, EN 11612, and ASTM D6413. Just because a fabric is fire-retardant does not mean it’s good; they also need to add other properties to the fabric, such as a certain ratio of fibres, a specific pattern of weave, and a certain finish to the fabric.
So, flame retardant fabrics create a barrier that is better than regular textiles. Protecting public safety, they create a controlled response for all flame-retardant fabrics for any type of fabric fire emergency for the safety of the workers and consumers. Industrial fire emergencies can provide a safety system built around the fire emergency response required for today’s industries.
History of the flame retardant fabric
In ancient Greece, the first flame resistant textiles were made by weaving fabric with fireproof asbestos fibres (Smith, 1983). However, the first attempt to chemically treat fabric to make it flame-resistant was in 1735 Obadiah Wyld patented a flame retardant treatment using alum and other mineral salts on textiles (Lewin and Sello, 1994). Flame-retardant finishes on fabric have been a scientifically approached issue since the 18th century.
The most significant advancement occurred with the introduction of synthetic fibres and chemically treating them with flame retardants to make them fire-resistant in the 1960s.
Nomex, introduced by DuPont in 1967, was an aramid fibre with heat-stable properties and became the industry standard for firefighting and military use (DuPont, 1967). This was also the introduction of Kevlar, a high-strength fibre for heat used in high-temperature applications (Hearle 2001).
Flame-retardant technology and particularly cotton with a flame-retardant finish became widespread and were used in Oil and Gas and electrical workers’ clothing due to their comfort and low price (Nelson 2000).
By the closing decades of the 20th century, legislation NFPA 2112 (2001) and EN ISO 11612 in Europe regulated and standardised flame retardant fabrics required for safety in the workplace.
The 21st century has brought forth greater emphasis on the use of phosphorus-based and halogen-free flame retardants due to health and environmental concerns.
Manufacturing Process of Flame Retardant Fabric
From selection to the final output, here is a detailed manufacturing process of flame retardant fabric:
1. Fiber Selection
There are numerous types of fire-resistant fabrics available, and first, it is crucial to choose the correct fiber type. Manufacturers often use flame resistant fibers. These include aramids, modacrylics, polybenzimidazole (PBI), FR viscose, and specific treated cellulosic fibers.
These fibers sustain natural flame stability and char formation. If fibers are needed cheaply, then flame-retardant treated cotton or cotton blends are suggested. Fiber selection not only determines flame resistance, but also comfort, strength, breathability, and long, durable endurance.
2. Weaving / Knitting Process
The fiber is spun into yarns, then woven or knitted into fabrics, depending on the intended use. For industrial protective wear, twill, ripstop, and plain weaves are common, and they enhance durability and tear resistance. Uniform fabrics often use blended yarns.
However, some specialized environments may require tighter yarn constructions for additional protection. The final flame-retardant performance is influenced by fabric weight, weave density, and yarn type.
3. Finishing Techniques
When fabric does not possess flame resistance, it undergoes chemical treatments. Phosphorus, DFR, polymer grafting, and ammonia curing for cotton are examples.
After treatment, the fabric gets cured, washed, neutralized, and the fabric undergoes performance testing. Some FR fabrics are multifunctional and therefore receive additional treatments like oil, moisture, or static repellents.
Properties & Characteristics of flame-retardant fabric
1. Flame Resistance
Flame retardant fabrics create a barrier between the user and heat exposure. They also prevent flame spread and can slow it down. They self-extinguish when the heat source is removed, mitigating the risk of severe burns. This is dependent on the fabric construction and the thermal treatment of the fibres.
2. Thermal Stability
These fabrics also protect the user from melting, dripping, or disintegrating when people are exposed to extreme heat. This is very important for people like firefighters, industrial workers, and military personnel. In long thermal exposures, inherently FR fibres outperform chemically treated fibres.
3. Char Layer Formation
Heat protective flame-retardants develop unique structural char layers. These layers shelter the skin from further injury by trapping in the heat and slowing down combustion. Char formation is one of the main metrics used to assess the performance of FR materials.
4. Non-Melting Behaviour
Most FR fabrics do not melt or stick to the skin when exposed to fire, unlike synthetic fabrics like standard polyester or nylon, thus greatly decreasing the severity of the burn. The non-melting nature of Aramids and FR viscose fibres is especially prized in this context.
5. Durability
Fire-retardant fabrics are designed to retain functionality after getting washed, and getting rubbed against other surfaces, and being used daily for a long period of time. FR fibres are inherently more durable and retain their protective properties, while treated fabrics lose their effectiveness at retaining durability. Durability in fabrics is especially of concern in harsh work environments.
6. Comfort and Breathability
Modern materials that are flame-retardant are more comfortable to wear, thanks to their more lightweight and moisture-wicking fabrics. FR fabrics that have a cotton base are really breathable, and are more favourable to wear in hotter conditions or if a person is on the job for a long period of time.
7. Chemical Resistance
Numerous FR textiles, like those of aramid or modacrylic blends, contain additional protective qualities that resist industrial chemicals, oils, and solvents. This makes FR products appropriate for high-risk and dangerous workplaces like refineries, chemical plants, or manufacturing facilities.
8. Electrical Arc Protection
There are some types of flame resistant textiles that are able to minimize the chance of ignition due to arc flashes and thereby provide arc flash protection. This makes the materials useful in electrical utilities and in power distribution, as well as in engineering environments that are prone to random electrical faults.
9. UV Resistance
As well as other FR materials like aramids, some of the FR fibers have very good UV resistance and can withstand prolonged exposure to the sun. This makes these materials very appropriate for outdoor applications for outdoor workers, military gear, or for industrial applications that require extended exposure to the sun.
10. Moisture Management
Modern turnkey FR textiles feature technologically advanced moisture management and moisture-wicking technologies that effectively eliminate moisture to keep the wearer dry and cool. This functionality is of great importance in physically demanding tasks or roles as it aids in comfort maintenance and helps prevent heat stress by providing a microclimate under protective clothing layers.
Applications of flame-retardant fabric
Due to the risk of Fires, Heat, Electrical Incidents, or Sparks, Flame retardant fabrics are needed across multiple sectors. They are needed as an extra level of protection for the PPE due to the potential for burn injuries. All industrial and commercial sectors use FR fabrics to guarantee the safety of the end user due to the pre-determined safety requirements of the contractor.
Flame retardant textiles are also used in commercial sectors such as FR interior decorations, transport, and public construction. FR outlines, and other documents targeted to Linen, Fixtures, and Upholstery are designed for public use (aircraft, theatres, auditoriums, etc.), and FR for curtains in venues are a legal requirement for public safety and risk reduction. FR fabrics also provide added fire safety in protective surrounds of civilian populations.
Key application areas:
- Oil and gas: Fire protection covers, jackets, and extreme protective PPE.
- Electrical and Utilities: Protection PPE for archives, rated for protection from electrical arcs.
- Fire Services: Turnout gear, multi-layer, FR Fabrics, Aramid.
- Manufacturing: FR Work uniforms for welding, metal, and hot work environments.
- Commercial: FR curtains, upholstery, etc. FR for cinema fabrics and FR for aircraft.
Variations and main types of flame-retardant fabric
Flame retardant fabrics come in a wide variety, each manufactured with different fibre mixtures, performance characteristics, and functional characteristics.
Flame retardant fabrics can be classified into two major categories: inherently flame resistant fabrics, which shield from fire due to the fibre chemistry, and treated fabrics, which acquire the attributes from chemical treatments after weaving. They all perform differently and have different durability and different fitness for various industries.
In many cases, inherently FR fabrics are more preferred in high-risk industries due to the long-term performance; however, for general industrial applications, treated fabrics are cheaper and more economical.
Furthermore, manufacturers bring in blended mixes to achieve a less complex and more employer-friendly alternative, combined with the abilities of fabric strength, moisture management, and multi-hazard moisture.
Main Types:
- Aramid Fabrics (Nomex, Kevlar blends): Very high heat stability. Non melting. Used for military and firefighters.
- Modacrylic Blends: Soft, self-extinguishing. Used in workwear and uniforms.
- FR Cotton / Cotton Blends: Widely used in oil & gas. Inexpensive treated cotton offering protection.
- PBI (Polybenzimidazole): Used in firefighting and other high-thermal zones. Offers premium thermal protection.
- FR Viscose: Often used in blends for better comfort wearability. Improves inherent FR properties.
- CarbonX / Carbon-Based Fabrics: Very high heat resistance. Used in particularly specialized environments.
Environmental impact of flame-retardant fabric
The type of fibre, chemical technologies, and the lifecycle of the fabric all play an important role in the environmental impact of flame retardant materials. Inherently flame-resistant fibres, like aramids and PBI, need polymerization processes that consume a great deal of energy, which increases the carbon footprint.
That being said, these fabrics last much longer and do not have to go through additional chemical treatments, which means that their environmental impact is lower during the use phase.
With regard to sustainability, there are additional issues concerning the treated cotton fabrics that stem from the use of cotton farming, the farming processes, and the chemicals that are used in the finishing processes.
Because of the toxicity, persistence, and environmental accumulation of traditional halogenated flame retardants, many manufacturers have pivoted to using safer phosphorous, nitrogen-based, and halogen-free flame retardants that have significantly better toxicological and environmental profiles.
The use of water and the energy involved are the foremost issues when considering the environmental footprint of the manufacture of FR fabrics.
Although modern mills use closed-loop water systems, low-temperature curing, and green chemical strategies to minimize their footprint, high temperatures and significant water usage are still required in dyeing, curing, and finishing processes.
Despite their intensive production, flame retardant fabrics contribute positively to sustainability through long service life.
Comparison Table
| Feature | Inherent FR Fabric | Treated FR Cotton | Aramid Fabrics |
| Flame Resistance | Permanent | Good but decreases over time | Excellent, non-melting |
| Comfort | High (viscose blends) | Very high | Moderate |
| Durability | Very high | Medium | Very high |
| Cost | Higher | Moderate to low | Higher |
| Applications | Military, firefighting, utilities | Oil & gas, industrial | Firefighting, aerospace |
References
- Dupont. (1967). Nomex technical data sheet. DuPont Corporation.
- Hearle, J. W. S. (2001). High-performance fibers. Woodhead Publishing.
- Horrocks, A. R., & Price, D. (2008). Advances in flame retardant materials. Woodhead Publishing.
- Lewin, M., & Sello, S. B. (1994). Handbook of fiber science and technology: Chemical processing of fibers and fabrics. CRC Press.
- Nelson, G. (2000). Fire and flame protection. Journal of Industrial Textiles, 30(2), 103–123.
- Smith, R. (1983). Ancient asbestos use. Classical Antiquity, 2(1), 42–55.
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