Key Takeaway: Comfort creep happens when workers start loosening or modifying their FR clothing because it feels too hot or restrictive. This puts them at risk for arc flash injuries. Safety managers can reduce this behavior by choosing inherently moisture-wicking fabrics and using field observations to catch compliance issues early.

 

Comfort creep happens when workers loosen or adjust their FR clothing to cool down, like rolling up sleeves, unbuttoning collars, or leaving shirts untucked. These small changes may offer relief in the moment, but they can seriously weaken the garment’s ability to protect.

In high-risk environments, even minor gaps in coverage can let an arc flash reach the skin. For example, when a shirt isn’t tucked in, that flash can travel underneath and cause burns. Brad Sipe, Director of Business Development for Lakeland’s High-Performance FR line, explains it plainly: 

“If there’s an arc flash that can come up underneath your shirt and burn you. If your shirt’s tucked in, there’s no place for that electrical arc to get underneath.” 

That’s the real risk of comfort creep. It turns an FR garment into a false sense of security. To address it effectively, we first need to understand what causes workers to adjust their gear in the first place.

What causes workers to adjust or loosen their FR gear?

Heat is the biggest trigger. Summer months are when you see the most sleeves rolled up, shirts untucked, or collars open. Workers in utilities, construction, and oil and gas already face intense heat and humidity. Add heavy PPE, and it becomes nearly impossible to stay cool without making adjustments, sometimes unsafe ones. 

OSHA identifies protective clothing as a major contributor to heat stress, especially during intense physical work in hot conditions. That’s exactly the challenge safety managers face in the field, when gear traps heat, workers look for ways to cool down, even if it breaks protocol. As Brad Sipe puts it, “Hot is hot. If you can be drier, you have a better chance of staying compliant out there. It’s just a fact.”

When workers start making changes, it often follows a pattern. Let’s look at what that behavior typically involves.

How do workers modify FR clothing on the job?

When FR gear feels too hot or restrictive, workers often make small adjustments to stay comfortable. The most common behaviors include:

• Rolling up sleeves
• Untucking shirts
• Leaving cuffs or collars unbuttoned

These quick fixes might offer relief, but they break the protective envelope FR clothing is designed to create. And most workers know better. “Everybody’s been told to tuck in their shirts,” Brad said, “but not a lot of these guys do. It’s just not enforced enough. And when you’re moving all day, your shirt tail can work its way out anyway.”

Even when rules are clear, staying compliant often comes down to habit, comfort, and supervision. That’s why spotting these behaviors early, before they lead to injuries, is key for safety managers.

How can safety managers identify and address comfort creep early?

Comfort creep usually doesn’t show up in reports, it shows up in the field. That’s why proactive, on-the-ground observation is key.

Look for early signs during routine walkthroughs: rolled sleeves, untucked shirts, or unbuttoned collars. These aren’t just dress code issues, they’re indicators that workers may be prioritizing comfort over protection.

To catch these patterns before they lead to incidents, safety managers can use:

• Clothing-focused field audits that go beyond general PPE checks
  
• Photo documentation (with worker consent) to track common modifications
  
• Supervisor spot checks during high-heat tasks or critical operations
  
• Wear trial feedback loops that reveal what’s working, and what’s not, in real time

Pairing these efforts with a behavioral safety approach strengthens the results. When field observations are followed by coaching and positive reinforcement, compliance improves, and incident rates go down. Research supports this: structured observation programs have been linked to measurable gains in PPE use and reductions in workplace injuries.

Still, prevention doesn’t stop at observation. The right gear can make compliance easier from the start.

How is high-performance FR clothing different from standard FR gear?

Not all FR is created equal. Traditional FR cotton can get heavy and soggy in the heat. Once saturated with sweat, it acts like a heat blanket, trapping warmth and making the body work harder to cool down. This leads to more fatigue and greater risk of heat illness.

That’s where high-performance FR (HPFR) garments come in. These are made with engineered blends of inherently flame-resistant fibers that wick moisture permanently. Brad explains:

“We tested all the fabrics in the market and found a 60% hydrophobic, 40% hydrophilic blend that works far superior. We put that into all our knit shirts, mid weight garments, and our outerwear.”

This blend pulls moisture away from the skin and moves it through the garment for faster drying. Each layer then transfers moisture to the next through a process known as WVTR, or water vapor transmission rate, which only inherent moisture-wicking blends provide. 

The result is less clamminess, higher breathability, and more consistent thermal regulation. That leads us to two standout FR technologies that help workers stay cool and protected without compromise.

What makes HyperLite and DH Air effective for preventing comfort creep?

Once you understand the causes of comfort creep, the next step is choosing gear that helps prevent it. Two standout options, especially for linemen and electrical workers, are HyperLite and Westex DH Air. Both are designed to boost comfort without sacrificing protection.

HyperLite

A Category 2-rated knit shirt that’s one of the lightest in its class.

• Engineered for single-layer or base-layer use
  
• Uses the 60/40 moisture-wicking fiber blend
• Moves moisture quicker and dries faster

Westex DH Air

A lightweight woven shirt that’s also Cat 2 rated.

• Made from breathable Westex fabric
  
• Wicks and dries faster than most woven FR shirts
  
• Offers a lighter feel with great airflow

These high-performance options address comfort creep at the source, by keeping workers cooler, drier, and more likely to stay compliant from the start.  If your current gear isn’t cutting it, there’s a clear next step to improve comfort, safety, and buy-in across your team.

What’s the next step if your FR program isn’t working?

If your current FR gear leaves workers overheated, uncomfortable, or cutting corners, it’s time for a change. You don’t have to choose between protection and comfort, you can have both.

Lakeland Industries has spent over four decades designing real-world FR solutions for high-risk environments. Their High-Performance FR (HPFR) line is built for industrial athletes, people who work hard, move fast, and face extreme heat on the job.

With advanced fabrics like HyperLite and Westex DH Air, your crew gets breathable, moisture-wicking comfort that keeps them focused, protected, and compliant all day long. Don’t wait for comfort creep to become a safety risk. Request a wear trial today and see the difference real performance makes.

FAQ

What is comfort creep in flame-resistant clothing?

Comfort creep happens when workers adjust their FR gear, like rolling up sleeves or untucking shirts, because it feels too hot or restrictive. These changes weaken protection and increase the risk of arc flash injuries and heat stress.

Why do workers loosen or modify their FR clothing?

Heat is the main driver. When FR garments trap heat and sweat, workers often untuck shirts or unbutton collars to cool down, even if it means breaking safety protocols.

How can safety managers prevent comfort creep on the job?

Use field audits, spot checks, and feedback from wear trials to catch compliance issues early. Pair these efforts with high-performance FR gear that’s built for breathability and moisture wicking.

What’s the difference between high-performance and traditional FR clothing?

High-performance FR (HPFR) garments use inherently flame-resistant, moisture-wicking fibers. Unlike treated cotton, they dry faster, breathe better, and stay cooler, helping workers stay safe and compliant.

Which FR shirts help reduce heat stress and improve compliance?

HyperLite and Westex DH Air are two top options. Both are Cat 2 rated, lightweight, and designed to move moisture efficiently, reducing discomfort and the urge to adjust gear.