Flame Retardant Workwear Guide: HRC1, HRC2 and ATPV

Flame retardant (FR) workwear protects people who work near electrical arcs, flash fires, sparks and heat. Electricians, utility crews, mining and oil and gas workers, refinery and chemical plant staff, welders and some manufacturing teams rely on it. Choosing it well means understanding what FR clothing does and does not do, what the HRC and ATPV ratings mean, and which garments suit your tasks.

This guide explains the basics, the HRC1 and HRC2 ratings commonly used in Australia, what to look for in fabric and construction, and examples from our FR clothing range.

What FR clothing does (and doesn't do)

FR clothing is designed to protect the wearer from thermal exposure and intermittent flame. It is not fireproof, and it will not keep flames away from you. What it does is:

  • Resist ignition better than ordinary fabric.
  • Self-extinguish once the ignition source is removed, rather than continuing to burn.
  • Not melt or drip onto the skin.
  • Insulate against the heat of a short exposure, such as an arc flash.

The goal is to reduce burn injuries and give the wearer the seconds needed to escape. That is why FR workwear has always been about improving the chances of survival and escape, not working inside a fire.

You will see both "flame retardant" and "flame resistant". In everyday use they mean the same thing: garments made from fabrics that are either inherently flame resistant (the fibre itself resists flame, such as modacrylic or aramid) or treated to be flame retardant (often cotton).

Primary and secondary protection

Primary protection garments are designed for activities with direct, deliberate exposure to flame or heat, such as firefighting. Secondary protection garments are designed for work where flame or arc exposure is possible but intermittent and unplanned. Most FR shirts, pants, jumpers and coveralls used by electricians and industrial workers are secondary protection.

Who needs FR workwear?

Anyone whose risk assessment identifies flame, arc or heat hazards. The main hazard groups are:

  • Electric arc: electricians, linesmen, utility and maintenance workers working on or near energised equipment.
  • Flash fire: workers in refineries, oil and gas, chemical and pharmaceutical plants where flammable gases or vapours may be present.
  • Combustible dust: workers in pulp and paper, food processing and similar plants where fine dust can ignite.
  • Sparks and heat: welding, mining and heavy manufacturing.

Your employer's risk assessment and site rules decide the required rating. Clothing is the last line of defence, after isolating the hazard and safe work procedures.

HRC1, HRC2 and ATPV explained

For arc flash protection, garments are tested to find their arc rating, usually given as an ATPV (Arc Thermal Performance Value) in calories per square centimetre (cal/cm²). The ATPV is the incident energy a fabric can block before the wearer would likely get a second-degree burn. A higher number means more protection.

Arc ratings are grouped into Hazard Risk Categories (HRC), now often labelled PPE categories (so you will see "HRC2/PPE2" on many labels):

  • HRC1 / PPE1: minimum arc rating of 4 cal/cm². Typically a single layer of FR shirt and pants for lower-energy tasks.
  • HRC2 / PPE2: minimum arc rating of 8 cal/cm². The most common rating for electrical and industrial FR workwear.
  • HRC3 / PPE3: minimum arc rating of 25 cal/cm², usually achieved with layered garments or heavier outerwear.
  • HRC4 / PPE4: minimum arc rating of 40 cal/cm², for the highest-energy tasks, usually a full arc flash suit.

An HRC rating describes arc flash protection. "FR" on its own only tells you the fabric is flame resistant. When buying, check for the actual HRC/PPE category and ATPV value on the label, and match it to the rating your task requires. Layering FR garments can increase total protection, but the combined rating comes from testing, not from adding numbers together.

What to look for in FR garments

Fabric

Common FR fabrics include:

  • Modacrylic and cotton blends (often around 55–61% modacrylic): soft, breathable and inherently flame resistant.
  • Para-aramid added to blends for strength and abrasion resistance.
  • Lyocell (Tencel) blended in for softness and moisture handling.
  • FR-treated cotton drill: a familiar, comfortable cotton feel.
  • Anti-static or carbon fibre (1–2%) to limit static build-up, which matters in areas with flammable gases or dust.

Ripstop weaves add tear strength without much weight. Lighter fabrics (around 160–230 GSM) help reduce heat stress in Australian conditions while still achieving HRC2 in many garments.

Construction details

  • FR components throughout: FR thread, FR press studs or buttons, and FR zips or zip flaps. Some garments have no metal components at all, which removes conductive and heat-holding hardware.
  • Concealed closures and covered plackets that reduce snag points and protect the zip line.
  • Gusseted sleeves, articulated knees and gusseted crotches for movement without riding up and exposing skin.
  • Ventilation via mesh underarm vents or vented backs, which is important in heat.
  • Closed-front shirts and coveralls where full coverage matters.

Hi-vis and FR together

Many FR garments are also high visibility, which suits road, rail, mining and utility work. Two things matter here:

  • The hi-vis fabric should meet AS/NZS 4602.1 for the class you need (day, night, or day and night).
  • The reflective tape must itself be FR. Ordinary reflective tape can melt or burn. Look for FR retroreflective tape (such as Sto-nor 9801, 3M FR tape or Reflectec FR tape) and, for night use, tape meeting AS/NZS 1906.4.

What to wear underneath

FR outerwear can be undermined by what is under it. Non-FR synthetic fabrics such as nylon, polyester, acetate and rayon can melt onto the skin if the outer layer is exposed to enough heat. Wear FR or natural-fibre base layers under FR garments, as your site rules specify.

Examples from our FR range

These garments show how the features above come together. Always check each product page for the current rating and specification.

Shirts

Women's fit

Pants

  • DNC Flamearc HRC2 Cargo Pants 3473: 230 GSM ripstop (61% modacrylic, 30% cotton, 5% para-aramid), anti-static, no metal components, front pockets and side flap cargo pockets.
  • DNC Flamearc HRC2 FR Taped Pants 3471: the same ripstop family with FR reflective tape above the knee, FR YKK nylon zip, FR press studs and double FR stitching.
  • Hard Yakka FR Cargo Pant Y02520: HRC2 with a minimum ATPV of 8.4 cal/cm², ShieldTec FR fabric, anti-static fibre, articulated knees and a gusseted inleg. Made for mining, energy, and oil and gas.

Jumpers, jackets and coveralls

  • DNC Hi-Vis 1/2 Zip FR HRC2 Jumper 3423: 280 GSM fleecy (60% modacrylic, 39% cotton, 1% carbon anti-static), rated HRC2 with an ATPV of 8+ cal/cm². Has an FR flap over the zip, an FR-flapped chest pocket and FR elastic cuffs and waistband. Sizes XS–6XL.
  • Bisley Taped Hi Vis FR Wet Weather Shell Jacket BJ8110T: a three-layer jacket (anti-static polyester outer, PU waterproof coating, 345 GSM modacrylic/cotton FR lining), fully seam sealed, with a detachable hood and Sto-nor 9801 FR tape. Listed as HRC3 with an ATPV of 32 cal/cm².
  • DNC Patron Saint FR Arc Rated Coverall 3427: 311 GSM cotton drill with an ATPV of 14 cal/cm², 3M FR tape, gusset sleeves and an Oeko-Tex 100 certificate for skin contact.

Branding FR workwear

Companies often want their logo on FR uniforms, but decoration needs care. Standard embroidery thread and many printed transfers are not flame resistant and can melt or ignite, which can compromise the garment where they sit. We can embroider FR garments using fire retardant thread made for logo embroidery. Ask us about FR-safe decoration before ordering, and keep logos clear of reflective tape.

We stock FR workwear from DNC Workwear, Syzmik, Bisley Workwear, Hard Yakka and KingGee, and deliver Australia-wide, including Sydney, Melbourne, Brisbane, Perth, Adelaide, Canberra, Darwin and Hobart.

Caring for FR garments

  • Follow the manufacturer's care label exactly. Many FR garments are designed to keep their protection through repeated washing when cared for correctly.
  • Avoid bleach, fabric softener and starch unless the label allows them, as they can affect FR performance or leave flammable residue.
  • Remove oil, grease and other flammable contaminants promptly. A contaminated garment can burn even if the fabric is FR.
  • Inspect garments regularly. Retire any with holes, tears, worn-thin areas, damaged tape or non-FR repairs.

Frequently asked questions

What is the difference between HRC1 and HRC2?

Both are arc flash protection categories. HRC1 garments have a minimum arc rating of 4 cal/cm². HRC2 garments have a minimum of 8 cal/cm², so they suit higher-energy tasks. Your risk assessment sets the category you need.

Is flame retardant clothing fireproof?

No. FR clothing resists ignition, self-extinguishes and won't melt onto the skin. That reduces burns and buys time to escape, but it does not make you immune to fire.

What does ATPV mean on an FR garment?

Arc Thermal Performance Value. It is the arc energy, in cal/cm², that the fabric can block before a second-degree burn is likely. Higher is more protective.

Can FR workwear also be hi-vis?

Yes. Many FR shirts, pants, jumpers and jackets combine fluorescent fabric meeting AS/NZS 4602.1 with FR reflective tape. Ordinary hi-vis garments are not FR.

Can I put my company logo on FR clothing?

Yes, but use FR-compatible decoration such as embroidery with fire retardant thread. Ask us about FR-safe decoration before ordering.

Is there FR workwear made for women?

Yes. Women's-fit FR shirts such as the Bisley BL8339T and Syzmik ZW170 offer the same protection with a better fit.

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