FR Clothing in the Automotive Industry: Where is it commonly used?

Automotive manufacturing involves much more than assembling vehicles. From welding and metal fabrication to maintenance, electrical systems and component production, employees work in environments where the hazards can vary significantly.
For workers exposed to flames, sparks, heat or related thermal hazards, FR Clothing can play an important role in workplace protection. However, not every employee in an automotive facility faces the same risks. A welding technician, maintenance engineer and assembly-line operator may work in the same factory but require different types of protective clothing.Understanding where FR Clothing is commonly used helps automotive manufacturers identify which roles may need additional protection and how protective garments fit into their wider workplace safety practices.

Why FR clothing matters in automotive manufacturing?

Modern automotive facilities combine machinery, electrical equipment, metalworking operations and increasingly complex production technologies. While some employees work in controlled assembly areas, others may regularly encounter welding sparks, hot metal, heated equipment or electrical hazards.
FR Clothing is designed for working environments where flame-resistant protective clothing is appropriate for the identified risks. However, the term FR does not automatically mean that a garment protects against every thermal or electrical hazard. The requirement for FR workwear should therefore be determined through a workplace risk assessment that considers the actual tasks employees perform.

Where is FR clothing commonly used in automotive manufacturing?

The following areas may require flame-resistant protective clothing, depending on the manufacturing process and workplace hazards.

1. Welding and body-in-white operations:

Welding is one of the most common automotive manufacturing applications where Flame Resistant Clothing may be required. During body-in-white production, individual metal components are joined to form the vehicle’s body structure. Depending on the process, employees may work around manual welding stations, robotic welding systems or related maintenance activities.
These processes can involve sparks, welding spatter and hot metal. Workers exposed to these hazards may require protective jackets, trousers, overalls or other garments designed for welding applications.
For a technical reference, the ISO 11611:2024 standard for protective clothing used in welding specifies safety requirements and test methods for clothing intended for welding and allied processes.
However, clothing requirements still depend on the actual exposure. For example, an employee working outside a properly enclosed robotic welding cell may face different risks from a technician entering the cell to perform maintenance. FR garments should therefore be selected according to the welding process, employee responsibilities and identified hazards.

2. Cutting, grinding and metal fabrication:

Automotive production frequently involves cutting, grinding, drilling and shaping metal components. Some of these activities can generate sparks, hot particles or heated surfaces. Employees may also perform fabrication work when repairing components, producing prototypes or modifying equipment. FR Clothing may be appropriate where the risk assessment identifies thermal hazards requiring flame-resistant protection.
However, the presence of sparks does not automatically mean every employee needs identical protective clothing. The selection also needs to consider other PPE, including face protection, gloves, safety footwear and equipment appropriate to the task. The objective is to ensure that the complete protective system addresses the hazards employee’s encounter.

3. Foundry, casting and forging operations:

Some automotive manufacturers operate foundries, forging units or other high-temperature metal processing facilities. These operations can expose workers to significant thermal hazards, including radiant heat, hot surfaces and potential contact with molten materials.
Such conditions may require specialised protective clothing.
For certain tasks, an FR suit may be appropriate as part of the protective system. However, ordinary flame resistance alone does not establish whether a garment provides adequate protection against molten metal splashes or intense radiant heat.
The materials, garment construction and applicable testing must correspond to the specific hazard. Making a fabric flame resistant does not automatically mean the finished garment is suitable for every high-temperature industrial application. Automotive companies should therefore examine the protective capabilities of complete garments rather than relying only on fabric descriptions.

4. Industrial maintenance and equipment repairs:

Maintenance teams often work across multiple departments within the same automotive facility. Their responsibilities may include machinery repairs, welding, cutting, equipment installation and electrical maintenance. Unlike employees assigned to a single production station, maintenance technicians may encounter different hazards throughout their working day.
Flame Resistant Clothing may therefore be necessary for particular tasks rather than for every maintenance activity. This becomes especially important during planned plant shutdowns, emergency repairs and equipment modifications. Maintenance managers should identify when FR workwear is required, ensure suitable garments are available and communicate the requirements before employees begin the work. Contractors carrying out similar activities should also be included in the relevant workplace safety arrangements.

5. Electrical maintenance and automated production systems:

Modern automotive manufacturing depends heavily on electrical machinery, control panels, robotics and automated production systems. Employees maintaining or servicing electrical equipment may encounter hazards that differ from those faced by general production workers. Where an assessment identifies an electric-arc hazard, appropriately rated protective clothing may be necessary.
An important distinction is that standard FR Clothing should not automatically be considered suitable for electric-arc exposure. The IEC 61482-2:2018 requirements for protective clothing against electric-arc thermal hazards address protective clothing intended for such applications. This standard concerns thermal hazards from electric arcs; it does not provide protection against electric shock itself. Electrical maintenance teams must therefore select suitable protective clothing and other PPE according to the specific electrical hazards involved.

6. FR Clothing in electric vehicle manufacturing:

Electric vehicle manufacturing has introduced additional electrical and battery-related processes into automotive production. Employees may work with battery packs, high-voltage systems, electrical connections and testing equipment. These operations can involve different hazards depending on the activity, equipment and energy involved.
However, not every employee working on an electric vehicle production line automatically requires FR Clothing. Battery assembly, electrical testing and maintenance activities should each be assessed individually. Where thermal or electric-arc hazards are identified, appropriate FR garments or other specialized protective equipment may be necessary. Protective clothing should complement engineering controls, safe operating procedures and other measures designed to minimize workplace risks.

7. Engineering workshops and temporary hot work:

Automotive facilities often have engineering workshops and tool rooms where employees manufacture, repair or modify equipment. Activities may include welding, grinding, cutting and other operations that create thermal hazards. Hot work may also take place outside designated workshop areas during plant expansion, installation or machinery repairs.
Because these activities are sometimes temporary, protective clothing requirements can be overlooked. Workplace procedures should address the hazards associated with the activity, including whether FR Clothing is required for employees and contractors carrying out the work.

8. Flame resistant outerwear for outdoor maintenance:

Automotive factories may have outdoor utilities, equipment installations and maintenance areas. Employees working in these locations may require weather protection while performing tasks involving thermal hazards. Where applicable, flame resistant outerwear can form part of the protective clothing system.
However, the outer layer needs to be compatible with the garments worn underneath and the protection required for the job. Ordinary jackets or weatherproof clothing should not automatically be worn overprotective garments without confirming that the combination is suitable. The complete clothing system should support both protection and practical working conditions.

9. Why different automotive departments may need different FR garments?

Large automotive manufacturers often aim to standardise employee uniforms across departments. While standardization can simplify workwear management, protective clothing should still reflect individual workplace hazards. A welder may require a different garment combination from an electrical maintenance technician. Similarly, an employee working in a foundry may need protection that is unnecessary for someone performing general vehicle assembly.
This does not mean every department requires a completely separate uniform program. Instead, manufacturers can group employees according to similar tasks, working conditions and protective requirements. The aim is to provide suitable FR Clothing without unnecessarily increasing garment complexity or restricting everyday work activities.

10. Managing FR Clothing across automotive facilities:

Managing protective workwear across a large automotive workforce involves more than garment selection. Different employees may require different sizes, garment combinations and protective specifications. Used clothing also needs appropriate collection, laundering, inspection, maintenance and replacement. These responsibilities can become more complicated when facilities operate multiple shifts or production departments.
A structured workwear program can help businesses manage garment availability and maintain consistent processes throughout the clothing lifecycle. At Lindström, we support automotive manufacturers through our automotive industry workwear solutions. Our managed Workwear Service includes garment supply, fitting, laundering, maintenance, delivery and storage.
For organizations managing protective workwear, a managed approach can simplify garment-related responsibilities. Any specific FR garment requirements should still be confirmed against the identified hazards and the protective specifications of the garments available.

Making FR Clothing part of automotive workplace safety:

FR Clothing can play an important role in automotive manufacturing where employees face heat, flame, sparks or related hazards. From welding and metalworking to industrial maintenance and certain electrical operations, the need for protective clothing depends on the work being performed.
For automotive manufacturers, the priority should be identifying where thermal hazards exist, determining the protection required and ensuring employees have suitable garments. A consistent approach to managing FR workwear can then help keep protective clothing available and in appropriate condition throughout its working life.

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