Eventually, every flame resistant garment reaches the age and condition that warrants its removal from service. Until that time, it is possible to make small repairs in order to extend the life of the garment. Any hole or tear in the flame resistant fabric leaves wearers vulnerable to burn injury should they be subjected to a thermal event. Proper repair of an FR garment necessitates following certain guidelines so that the protective performance of the garment is not diminished as a result of the repair.
It is essential that the fabrics and thread used for repairs are equivalent in performance to those used in the original construction of the garment. All Bulwark garments are sewn with aramid thread and the same should be used in any repairs attempted on the garment. Some users have established a practice of saving panels of fabric from retired garments as a source of cloth for mending garments still in service. Zippers, buttons, fasteners and other closure systems must meet basic heat resistance requirements; check with the garment manufacturer for a source of suitable trim and findings.
Although there are no strict guidelines given by any source, there are limitations on the extent of any repair. Rips, tears or holes that exceed 1" in length or diameter are likely too large to be safely repaired in the field. As a practical measurement, damaged areas suitable for repair should not exceed the size of a quarter. In cases where the affected area is larger, it is prudent to retire the garment. Fabric that has become thin or threadbare in spots due to heavy wear may provide reduced protection from heat; garments showing signs of heavy wear like this are probably nearing the end of their useful wear life and should be removed from service at the discretion of the wearer or in accordance with the safety policies of the employer.
ASTM International has developed two standards which describe the best practices for home and industrial laundering of FR garments. Both documents briefly address the repair and retirement of flame resistant clothing. For more details, consult ASTM F1449, Standard Guide for Industrial Laundering of Flame, Thermal and Arc Resistant Clothing, and ASTM F2757, Standard Guide for Home Laundering Care and Maintenance of Flame, Thermal and Arc Resistant Clothing.