Hot, Bothered, and Protected: Is Summer the Most Dangerous Time to Wear FR?

Rasco FR Workwear is specially designed to protect from the hazards of the heat. 

Welcome to the dog days of summer, where the air feels thick enough to chew, your boots melt into the pavement, and your flame resistant (FR) coveralls threaten to become a wearable slow cooker. This is the season of iced tea, triple digit thermometers, and very questionable decisions about safety gear. You might think the biggest hazard on a summer job site is heatstroke or sunburn. But what if the real danger is how we react to that heat—especially when we’re suiting up in gear that’s supposed to protect us? Let’s crack open the science, sweat, and stubborn myths behind FR clothing and summer safety. Spoiler Alert: the risk doesn’t melt away just because the calendar hits July. 

Here’s a dangerous little lie: “It’s summer, so FR risk is down.” After all, we associate flames with winter—furnaces, heaters, overloaded circuits, dry Christmas trees. Summer? That’s for pool time, pickleball and PTO. It feels safe. But in the world of industrial work, summer often increases the risk of fire and injury. Here’s why:

     • Increased electricity use: Cooling systems and high-voltage equipment are pushed to the max, upping the chances of arc flashes and electrical fires.
     • More outdoor work: Welding, cutting, and grinding move outside. The combination of heat, dry materials, and open flame is a recipe for disaster.
     • Dehydration and fatigue: Workers overheat. When they do, their focus slips, their reflexes slow, and they make mistakes. Big, fiery, expensive mistakes.
     • Dry conditions: Especially in oil fields, gas sites, or rural construction zones, summer equals dry brush. A single spark can start a chain reaction faster than you can say “PPE.” So no, summer is not a free pass. It’s a different kind of danger—and one that catches far too many teams off guard.

Understandable instinct. When you’re drenched in sweat five minutes into your shift and your shirt could double as a wet towel, it’s tempting to think, “Maybe I’ll just unzip a little. Maybe I’ll skip the underlayer today. It’s only hot work…”But here’s the catch: FR gear doesn’t just protect you from direct flame. It also helps guard against arc flash, radiant heat, and contact burns. The second you start rolling up sleeves, opening collars, or ditching layers, you compromise the very protective gear designed to keep you alive. The dangerous tradeoff of what happens next is all too predictable:

That’s not a hypothetical. It’s the recurring pattern found in safety incident reports across industries. The solution isn’t less gear—it’s better FR gear. FR gear you’ll actually keep on while in the heat. 

Let’s break this down like a science segment on a late-night show.When the ambient temperature climbs and you’re encased in multiple layers, your core body temperature starts rising. Normal is about 98.6°F. But just a few degrees over that, and you’re in dangerous territory:

• At 100.4°F – mild heat stress sets in
• At 101.3°F – your body struggles to regulate itself
• At 104°F and above – you risk heat stroke, confusion, organ damage, and worse

All while you’re trying to focus on operating heavy equipment, navigating complex tasks, or avoiding literal flames. Your body’s cooling system (sweat + evaporation) goes into overdrive. But in non-breathable or heavy FR gear, that cooling process is seriously limited—unless you’re wearing gear built with ventilation, moisture-wicking fabric, and lightweight engineering.

So… Is FR Workwear Unsafe in the Heat? No. But badly designed FR Workwear is. Let’s be clear: properly designed FR gear doesn’t cause injuries. But poorly designed FR gear encourages behaviors that do. Uncomfortable, bulky, scratchy, or heat-retaining FR leads to:

     • Non-Compliance: People ditch the gear or wear it improperly
     • Distraction: Heat becomes the only thing workers can think about
     • Impaired Performance: Physically and mentally, heat breaks down safety awareness. 

The real issue isn’t the FR standard—it’s how that standard is executed. Flame resistance doesn’t have to mean heat entrapment. That’s where the next generation of FR comes in.

When the Rasco R&D Team designs the perfect summer FR garments, we take into account the following qualities:

Durability is critical, but so is wearability. Advances in fabric technology now allow for FR shirts and pants that weigh significantly less while still passing NFPA 2112 and ASTM F1506. Pro tip: Look for fabrics in the 5.0 – 7.0 oz range for summer.

Specially designed garments constructed with technical fabrics provide airflow without compromising protection. The more your body can self-regulate, the safer you’ll be.

Forget cotton that holds onto sweat like a sponge. Modern FR gear should pull moisture away from the skin and dry fast. This prevents chafing, reduces bacteria buildup, and helps your body cool more effectively.

Garments should move with you, not fight you. Action backs, articulated knees, and stretch panels can reduce friction points and improve comfort—essential when every movement feels like swimming through molasses.

Many FR fabrics offer a bonus: built-in UV resistance. When your crew is outside all day, this adds an extra layer of protection—literally.

Rasco doesn’t just meet industry safety standards—we meet the standard of human decency by not turning you into a walking sweat lodge. Our summer-weight FR gear includes:

• FR Polartec® Neck Gaiter – Ultra-lightweight and breathable, this neck gaiter features moisture-wicking technology engineered to keep you dry and comfortable on even the hottest days. It’s the perfect balance of coverage and airflow — so your neck stays protected from the heat, dust and sun without feeling like it’s wrapped in a sauna towel.

Rasco's new FR Polartec Neck Gaiters protect from heat, dust, wind & FR Hazards.

• FR DH Air Uniform Shirt – Made from Westex DH Air, our lightest and most breathable fabric yet, this shirt brings superior CAT 2 protection with cutting-edge air flow and moisture management tech. Plus, it’s designed with increased mobility, so you can move freely instead of feeling like you’re wrapped in a wet tarp.

Rasco's DH Air Shirts are the most comfortable and breathable FR shirts.

 

• FR DH Air Coverall – A full-coverage solution for high-heat work. Built with the latest in air flow and moisture control, this coverall doesn’t just check the CAT 2 compliance box — it moves with you, thanks to an action back and mobility-focused design. Suit up without sweating out your will to live.

 

Rasco's FR DH Air Coveralls are designed with breathability and enhanced mobility.

 

• FR Henley – The classic look, upgraded for hot workdays. Constructed with an interlock knit weave for enhanced mobility, stretch, and air flow, this tee brings a cool, breathable feel with CAT 2 protection. It’s your go-to for the jobsite or just pretending you’re off-duty.

 

Rasco's FR Henleys are breathable and comfortable.

Summer hazards aren’t just about sun and sweat. Think big picture.

     • Humidity affects evaporative cooling: 90°F in Phoenix feels survivable; 90°F in the Deep South feels like death in a wet sock.
     • Altitude can change oxygen levels and increase fatigue.
     • Dust and grit in dry regions can degrade gear faster and irritate skin, especially when sweat is involved.
     • UV degradation can break down non-FR gear over time—your Rasco garment is designed to resist that.If you’re wearing FR gear that isn’t built with your region in mind, you’re not dressing for the job—you’re dressing for the ER.

 The Cost of Cutting Corners - Still tempted to let compliance slide “just for summer”?Let’s talk economics for a hot second:

     • Direct cost of a burn injury: $100,000+
     • Lost workdays: Up to 30+ days per incident
     • OSHA citations: $15,000 to $150,000 per violation
     • Worker comp & insurance spikes: Substantial and lasting
     • Reputation damage: You can’t put a price on trust and morale.

Compare that to a Rasco shirt priced under $50, and the math starts to look embarrassingly obvious.

Want to get through the dog days of summer without becoming a cautionary tale? Here’s your cheat sheet:

More sweat = more water loss = more danger. Electrolytes help too. Just make sure your crew has access to cold, clean water all day. If you're feeling extra generous you can spring for the extra fancy water with electrolytes. 

Give your body a break. If you’re sweating through one set by noon, have a dry, clean backup ready.

Even a 10°F temperature drop in the shade can help reduce body temp. Use tents, trucks, or portable shade wherever possible. 

Don’t assume everyone knows the risks of partial compliance. Host quick summer safety refreshers—five minutes could save a life.

Your FR gear should be certified, comfortable, and season-appropriate. If it isn’t, it’s not just uncomfortable—it’s dangerous. 

FR hazards don’t care about your thermometer. Neither should your FR gear. Summer doesn’t eliminate fire hazards—it disguises them behind discomfort. The most dangerous time to wear FR isn’t summer, winter, spring, or fall. It’s anytime you’re tempted not to wear it properly. At Rasco, we make FR Workwear that you’ll want to wear—even in the heat of the summer. Because safety should be practical, not punishing.

 Ready to Upgrade Your Summer Safety? Shop the Rasco Summer FR collection here.