How To Wash FR Clothes: Complete NFPA 2113 Laundering Guide

Laundering flame-resistant (FR) garments correctly requires washing them separately in warm water below 140°F (60°C) using a neutral-pH liquid detergent free of fabric softeners, chlorine bleach, hydrogen peroxide, and soap-based fats. Following NFPA 2113 guidelines ensures you inspect garments for flammable soil buildup prior to washing and dry them at stack temperatures under 160°F (71°C) to maintain certified arc thermal performance values (ATPV).

Pre-Wash Inspection & Chemical Safety Prerequisites

Proper maintenance of flame-resistant workwear is a mandatory safety protocol governed by industrial occupational standards, including NFPA 2113 and OSHA 1910.269. Laundering FR apparel differs fundamentally from handling standard cotton or synthetic workwear because improper chemicals or thermal conditions can mask or permanently destroy the fabric's self-extinguishing polymer matrix or chemical treatment. Before starting any wash cycle, safety personnel and workers must evaluate water quality parameters, chemical formulations, and mechanical wear.

Essential Materials, Standards, and Operational Metrics

• Required Cleaning Agents & Equipment:
  
  
  • Standard heavy-duty liquid laundry detergent (neutral pH between 6.5 and 8.0)
  • Soft water source (water hardness maintained below 5.0 grains per gallon or 85 ppm)
  • Commercial or high-efficiency residential washing machine with adjustable temperature controls
  • Pre-wash spot treatment (citrus-based degreaser or liquid detergent concentrate without oxidizers)
• Mandatory Regulatory & Technical Standards:
  
  
  • NFPA 2113: Standard on Selection, Care, Use, and Maintenance of Flame-Resistant Garments
  • ASTM F1506: Standard Performance Specification for Flame Resistant and Electric Arc Rated Protective Clothing
  • OSHA 1910.269: Electric Power Generation, Transmission, and Distribution Safety Guidelines
• Duration & Cost Benchmarks:
  
  
  • Total Processing Time: 60 to 90 minutes per wash/dry cycle
  • Average Cost per Garment: $0.45 – $1.20 per cycle in utility and detergent expenditures
  • Expected Garment Lifespan: 30 to 50 wash cycles for chemically treated cottons; up to 100+ cycles for inherent aramid synthetics (e.g., Nomex, Kevlar)

The Complete Flame-Resistant Garment Laundering Protocol

Step 1: Pre-Wash Inspection and Garment Sorting

Before loading garments into the washing machine, conduct a visual and tactile inspection of every piece of clothing. Flame-resistant clothing works by starving flames of fuel and creating an insulating char layer. If the outer shell is coated with flammable contaminants such as hydraulic fluid, refined oil, grease, gasoline, or organic paints, the garment loses its protective efficacy regardless of fabric rating.

1. Turn all garments inside out to minimize surface abrasion on the outer protective face of the fabric and preserve high-visibility striping.
2. Fasten all hook-and-loop closures (Velcro), zip all heavy-duty metallic zippers, and button all plackets to prevent mechanical tearing or surface snagging during the wash cycle.
3. Sort garments into dedicated FR loads. Never mix flame-resistant clothing with non-FR apparel. Non-FR fabrics can shed lint (cellulose or polyester microfibers) that attaches to the FR fabric, creating a flammable outer layer that can ignite when exposed to an electric arc or flash fire.
4. Separate light-colored FR garments from dark-colored pieces to prevent dye transfer that could compromise high-visibility safety compliance (ANSI/ISEA 107).

Warning: Do not attempt to wash FR clothes contaminated with volatile chemicals or fuels in a household washing machine without a pre-soak or commercial degreasing cycle. Volatile hydrocarbons present a fire hazard inside closed drying drums.

Step 2: Spot Treating Heavy Soiling and Hydrocarbon Stains

Heavy industrial soils, grease, and oil must be extracted prior to standard wash cycles. Standard detergents alone will not break down high-viscosity petroleum products at safe washing temperatures.

1. Apply a concentrated, non-bleaching liquid detergent or an industrial citrus-based solvent directly to grease marks, collar soil, and cuff line grimes.
2. Gently rub the fabric against itself or work the solution into the weave using a soft-bristles nylon brush. Avoid harsh wire brushes that can break core fibers like Nomex or Westex UltraSoft.
3. Allow the pre-treatment solution to penetrate the fibers for 15 to 30 minutes at room temperature (70°F / 21°C).
4. For extreme hydrocarbon buildup, pre-soak the garments in a basin of warm water (maximum 105°F / 40°C) combined with half a cup of neutral-pH liquid detergent for at least two hours.

Step 3: Washing Machine Parameter Setup and Chemistry Selection

The washing stage requires strict control over water chemistry, mechanical agitation, and thermal input. Missteps here can leave mineral deposits that mask flame resistance or chemically degrade protective polymer chains.

1. Set the water temperature to warm, strictly keeping it below 140°F (60°C). High water temperatures accelerate color loss and cause excessive shrinkage in treated cotton FR fabrics.
2. Dose the machine with a heavy-duty liquid laundry detergent. Ensure the formula contains no chlorine bleach, hydrogen peroxide, oxygen-based stain removers, or fabric softeners.
3. Confirm that the detergent does not contain natural tallow soaps (such as sodium tallowate). Natural soap bars or soap powders react with minerals in hard water to form insoluble fatty acid scum (calcium stearate) over the fibers, which acts as a secondary fuel source if exposed to direct flame.
4. Select a normal or heavy-duty wash cycle with a comprehensive rinse cycle. Ensure the final rinse completely clears all suspended soils and residual detergent surfactants from the weave.

Pro-Tip: If your municipal water supply has a hardness level exceeding 5.0 grains per gallon (85 ppm), install a water softener or add a non-precipitating water conditioner to the wash cycle. Hard water minerals bond to FR fibers, lowering the thermal protective performance (TPP) rating over time.

Step 4: Drying and Thermal Conditioning

Improper drying is a primary cause of excessive shrinkage and mechanical wear in flame-resistant apparel. Over-drying weakens synthetic aramid blends and destroys cotton cell structures.

1. Transfer washed garments immediately to the dryer to prevent mildew formation and set-in creasing.
2. Select a low-to-medium heat setting on the dryer, ensuring the maximum stack exhaust temperature does not exceed 160°F (71°C).
3. Monitor the drying cycle closely and remove garments while they are still slightly damp (roughly 5% residual moisture) to minimize fabric shrinkage and eliminate the need for high-heat iron pressings.
4. If line-drying, hang garments out of direct sunlight. Extended exposure to ultraviolet (UV) radiation breaks down inherent aramid fibers (such as Nomex) and degrades synthetic high-visibility dyes.

Warning: Never use anti-static dryer sheets or liquid fabric softeners. Dryer sheets deposit a thin coat of wax, tallow, or silicone quats across the garment surface. This synthetic coating is extremely flammable and completely neutralizes the flame-resistant properties of the clothing.

Step 5: Post-Launder Quality Inspection and Storage

Laundering ends with a secondary quality control audit. An improperly maintained FR garment must be removed from service immediately.

1. Lay the clean garment flat under bright light and inspect all high-stress zones: crotch seams, underarms, pocket corners, and elbow cuffs.
2. Check for physical damage including open seams, frayed edges, small punctures, or broken closures. Unrepaired holes larger than 0.5 inches (12 mm) violate NFPA 2113 compliance.
3. Test fabric stiffness. If the fabric feels waxy or stiff, soap scum or chemical residues are present, requiring a strip-wash cycle (warm wash with no detergent and a non-precipitating water conditioner).
4. Store clean FR clothing in a cool, clean, dry environment away from direct light, volatile organic compounds (VOCs), and industrial chemical fumes.

Flame-Resistant Fabric Laundering & Chemical Compatibility Specifications

Different FR fabric technologies require distinct maintenance profiles. Inherent fabrics (where protection is built into the molecular fiber structure) behave differently during laundering than treated cellulosic fabrics (where flame resistance is polymerically bonded to cotton fibers).

Laundering Failures, Contamination Hazards, and Remediation

Scenario 1: Accidental Use of Fabric Softener or Dryer Sheets

• Root Cause: A laundry operator added liquid fabric softener during the rinse cycle or placed a dryer sheet in the dryer drum, coating the FR fibers with a flammable layer of fatty quaternaries or silicone compounds.
• Actionable Fix: Strip the coating from the garments by re-washing them immediately on a high-rinse setting using warm water (140°F / 60°C) and a half-cup of heavy-duty liquid detergent combined with a non-precipitating water-softening agent. Do not add detergent to the second rinse cycle. Inspect the fabric's absorbency post-rinse: if a drop of water absorbs into the cotton weave within 3 seconds, the wax coating has been successfully stripped.

Scenario 2: Mineral Deposit Build-Up from Hard Water (Soap Scum Scouring)

• Root Cause: Washing FR garments in hard water (exceeding 85 ppm calcium/magnesium) using natural soap powders or low-grade detergents, leading to insoluble calcium stearate deposits that burn readily under an arc flash event.
• Actionable Fix: Perform a strip-wash by running the garments through a warm wash cycle with a dedicated commercial chelating agent or non-precipitating water conditioner (such as sodium hexametaphosphate). Do not use home vinegar solutions, as strong acidic washes can damage the flame-retardant chemical bonds in treated cotton fabrics.

Scenario 3: Persistent Hydrocarbon or Fuel Odors After Washing

• Root Cause: The washing cycle failed to reach the emulsification threshold needed to lift deeply embedded oils, leaving flammable volatile organic compounds trapped inside the core threads.
• Actionable Fix: Remove the garment from service immediately. Pre-soak the affected item in a 10% solution of commercial industrial citrus degreaser and warm water for two hours. Re-wash independently on the maximum allowed thermal setting for that fabric type with a high-surfactant liquid detergent. If the hydrocarbon odor remains after drying, permanently decommission and destroy the garment.

Scenario 4: Premature Shrinkage and Fabric Distortion

• Root Cause: Drying FR clothing at high stack temperatures (exceeding 160°F / 71°C) or over-drying items past 0% moisture retention, causing cross-linked cotton fibers to contract severely.
• Actionable Fix: Prevention is the only remedy for permanent thermal contraction. While ruined items cannot be restored to original dimensions, future shrinkage can be halted by enforcing a strict removal policy when garments are slightly damp, followed by air-drying on wooden hangers.

Frequently Asked Questions

Can you wash FR clothes with regular clothes?

No, flame-resistant garments should never be washed alongside non-FR clothing. Standard apparel sheds lint composed of untreated cotton or flammable synthetics, which can adhere to the surface of the FR fabric and ignite when exposed to an heat source. Washing FR items separately also prevents accidental exposure to non-FR cleaning agents, such as fabric softeners used on regular laundry.

Does washing FR garments ruin their flame-resistant properties?

Washing FR garments correctly will not ruin their protective properties, especially if they are made from inherently flame-resistant fibers like Nomex or high-quality treated fabrics like Westex UltraSoft. However, using improper laundry additives—such as chlorine bleach, hydrogen peroxide, or fabric softeners—will degrade the protective treatment or coat the fibers in flammable chemical residue, destroying their protective capacity.

Is it safe to use starch or fabric softener on flame-resistant clothing?

No, both starch and fabric softeners are dangerous to use on FR clothing. Fabric softeners leave a flammable coating of silicone or tallow compounds over the fabric, while traditional laundry starches are made of complex carbohydrates that readily ignite under thermal stress. Both agents effectively mask the self-extinguishing capabilities of the garment.

What happens if you accidentally use chlorine bleach on FR garments?

Chlorine bleach chemically breaks down the flame-retardant polymers bonded to treated cotton fabrics, permanently degrading their protective capability after just a few washes. On inherent aramid fabrics like Nomex, chlorine bleach weakens the structural tensile strength of the individual yarns, leading to fabric thinning, tears, and mechanical failure during an arc flash or flash fire event.

Can you dry clean FR garments?

Yes, most flame-resistant garments can be safely dry cleaned, provided the dry cleaner uses pure perchloroethylene or hydrocarbon solvents and does not add flammable re-texturizing agents or finishes during the process. Dry cleaning effectively extracts heavy petroleum greases and industrial oils that home laundry cycles cannot remove. Always check the garment manufacturer's care label before dry cleaning.

Optimize Your Industrial Workwear Safety Program

Ensuring complete workplace safety requires strict adherence to laundering protocols, routine equipment inspections, and compliance with NFPA 2113 standards. Audit your team's laundry workflows and supply chains today to guarantee that every protective garment retains its life-saving capabilities over its operational lifespan.