FR Embroidery on Flame Retardant Workwear for Oil, Gas and Mining
Why FR garments need FR embroidery
A flame-resistant shirt is only as safe as the weakest thing stitched into it. Put a standard polyester logo on a $190 Tecasafe shirt and you have added a patch of thermoplastic that melts at around 250°C, drips, and sticks to skin. That one logo can turn a compliant garment into a non-compliant one and leave your crew with a burn exactly where your company name sits.
This matters most in oil, gas and mining. Flash fires on plant, arc flash near switchrooms, and molten metal from hot work are the hazards FR workwear is bought for. Site inductions and contractor PPE specifications on most Australian resources sites now require that any branding on FR clothing is itself FR. Many sites will refuse embroidered garments that cannot show FR thread was used.
At Flash Uniforms we embroider FR workwear for Perth crews heading to the Pilbara, the Goldfields and offshore. This guide explains what FR embroidery is, which Australian standards apply, how our process works, and which garments we embroider most.
What FR embroidery actually is
FR embroidery means every component added to the garment resists flame: the top thread, the bobbin thread underneath, and the backing (stabiliser) that holds the stitches. Standard embroidery fails on all three.
| Component | Standard embroidery | FR embroidery |
|---|---|---|
| Top thread | Polyester or rayon, melts ~250°C | 100% aramid (Nomex® fibre), no melt point, heat resistant to 300°C |
| Bobbin thread | Polyester, melts and drips | 100% aramid bobbin |
| Backing | Polyester or nylon cut-away, ignites or melts against skin | Kevlar® (para-aramid) backing, chars without melting |
| Seam thread | Not touched | FR thread used for any repair or hemming |
The thread is the obvious part, but the backing is the one most embroiderers skip. It sits directly against the wearer's skin on the inside of the shirt. If it melts in a flash fire it fuses to the body, which defeats the point of the garment.
The fabric itself is not changed by embroidery. Inherent FR fabrics like TenCate Tecasafe® Plus, modacrylic blends and aramid remain FR for the life of the garment. Treated cotton drill (DNC Patron Saint, for example) stays FR for its rated number of washes. Embroidery with the right thread and backing keeps the whole garment at its original protection level.
FR vs flame retardant vs flame resistant. These are used interchangeably in Australia. Strictly, "flame resistant" is the inherent property of the fibre, "flame retardant" describes a chemical treatment applied to the fabric, and "FR" covers both. All three describe fabric that self-extinguishes within two seconds of the flame being removed.
The Australian standards that apply
There is no single Australian standard called "FR embroidery". Instead, the garment is certified to a performance standard, and the embroidery must not drop it below that level. These are the standards you will see on FR workwear sold in Australia, and what each one means for branding.
| Standard | What it covers | What it means for embroidery |
|---|---|---|
| ISO 11612 | Clothing to protect against heat and flame. Codes A (flame spread), B (convective heat), C (radiant heat), D (molten aluminium), E (molten iron), F (contact heat) | Code A1/A2 requires limited flame spread on the whole garment, including seams and attachments. Polyester thread fails this. Madeira Fire Fighter thread is tested to ISO 11612 D and E |
| IEC 61482-2 | Protective clothing against the thermal hazards of an electric arc. Tested by open arc (IEC 61482-1-1, giving an ATPV or ELIM in cal/cm²) or box test (IEC 61482-1-2, APC 1 or APC 2) | The arc rating applies to the garment as supplied. Non-FR embroidery is an untested modification and most site specs treat it as voiding the rating |
| NFPA 70E / HRC and PPE categories | US system most Australian suppliers label with: HRC 1 / PPE 1 (4 cal/cm²), HRC 2 / PPE 2 (8 cal/cm²) | A PPE 2 shirt must stay PPE 2 after branding. FR thread and backing are the only way to keep that claim |
| ENA NENS 09-2014 | Australian national guideline for selecting, using and maintaining PPE for electrical arc hazards | The guideline Australian electrical and resources employers use to write their FR clothing specs. It expects all garment components, including logos and labels, to be flame resistant |
| AS/NZS 4836:2023 | Safe working on or near low-voltage electrical installations and equipment | Requires arc-rated PPE for work with an arc flash risk and points to NENS 09 for garment selection |
| AS/NZS 4602.1:2011 | High visibility safety garments for high-risk applications. Class D (day), N (night), D/N (day and night) | Embroidery cannot cover the minimum area of fluorescent background fabric or the reflective tape. We position logos to keep the garment compliant |
| AS/NZS 1906.4:2010 | Retroreflective and fluorescent materials for hi-vis garments | FR hi-vis uses FR reflective tape (3M Scotchlite FR or Sto-nor 9801). We never stitch through it |
| ISO 11611 | Protective clothing for welding and allied processes, Class 1 and Class 2 | Welder's jackets need FR thread that also resists spatter. Aramid thread does not melt when hit by molten droplets |
| EN 1149-5 | Electrostatic properties of protective clothing | Anti-static garments for gas and hydrocarbon plants. Embroidery does not affect the anti-static yarn but the thread should still be FR |
| AS/NZS 4501.1:2008 | Occupational protective clothing. Guidelines on selection, use and care | The general guide employers follow for PPE clothing, including who is responsible when a garment is modified |
What is legally required. Under the model Work Health and Safety Regulations, a PCBU (the employer or principal contractor) must provide PPE that is suitable for the hazard and maintained so it stays effective. If branding reduces the protection of an FR garment, the employer carries that liability, not the garment maker. This is why mine and gas site PPE specifications ask for FR thread as a condition of entry.
What certification does not cover. The garment's test certificate covers the garment as supplied by the manufacturer. Any embroidery is a post-certification modification. We cannot re-certify a garment, and neither can any other embroiderer. What we can do is use components that are themselves tested to ISO 11612 and ISO 15025 (flame spread) so the garment's protection is not reduced, and give you a written statement of the thread, bobbin and backing used for your site file.
How we embroider FR garments
Every FR job runs on a dedicated setup. Standard polyester thread never goes near it.
- We confirm the garment is FR. We check the care label and the manufacturer's rating (ISO 11612 codes, HRC/PPE level, arc rating). If you supply your own garments we check them the same way. If the garment is not FR, we will tell you rather than embroider it as if it were. Most of the garments and FR clothing that we embroider are sourced from reputable workwear suppliers in Australia, we need to cover ourselves as well as your workers with the best quality FR clothing to get the job done.
- We digitise for aramid thread. Aramid is thicker and has less stretch than polyester, so a design digitised for standard thread will pull and bunch. We re-digitise your logo at a lower density (around 4.0) with wider underlay and a 75/11 or 80/12 needle. Fine text under 5 mm high is simplified or dropped.
- We hoop with Kevlar® backing. A Kevlar (para-aramid) cut-away stabiliser goes behind the fabric. It holds the stitches, does not melt, and chars rather than burns if exposed. The excess is trimmed close, so nothing hangs loose against the skin. Special scissors are also required to cut the Kevlar as it is tough and blunts the scissors very easily.
- We stitch with Madeira Fire Fighter thread on top. Madeira Fire Fighter No. 40 is 100% aramid with Nomex® fibre from DuPont. It has no melt point, is heat resistant to 300°C, and complies with ISO 6941, ISO 15025 and ISO 11612 D and E. It comes in 24 to 30 colours matched to the Polyneon range, so most company colours can be matched to Pantone.
- We run a 100% aramid bobbin underneath. The bobbin thread forms the underside of every stitch and sits against the skin. We use Madeira's aramid bobbin, never pre-wound polyester. This is the step most often skipped by shops that only swap the top thread. This is where most embroiders will cut corners and use regular thread!
- We position for hi-vis compliance. On Class D/N garments the logo goes on the chest, sleeve or back yoke where it does not reduce the fluorescent area below the AS/NZS 4602.1 minimum, and never across reflective tape. We will never embroider your logo onto any place on the shirt that voids its compliance.
- We inspect and record. Each job is checked for thread breaks, loose backing and coverage. We note the garment, thread batch, bobbin and backing on the order so you can show your site what was used.
Care after embroidery. Fire Fighter thread can be washed at up to 95°C and its flame resistance does not reduce with washing. The garment's own care label still governs. Do not use bleach or fabric softener on FR garments, as both reduce the FR performance of treated fabrics and coat the fibres of inherent ones.
What we will not do. We will not use standard thread on an FR garment, embroider over reflective tape, use adhesive patches or heat transfers on FR workwear, or stitch logos onto garments we cannot confirm are FR. Each of those creates a burn risk or a compliance gap. On some instances where the client does request non-FR threads we will need this in writing so that we are covered in case anything goes wrong due to a non-compliant garment, before we do this, we will explain the risks involved and the ultimate final decision is yours. You may be wondering why bother, but trust us we do get requests like this all the time to save costs, but is a staff members safety more than $20.00?
FR garments we embroider most
These are the FR garments Perth oil, gas and mining crews order from us most often, all available with FR embroidery. Browse the full range in our Fire Retardant Clothing collection, or by type: FR shirts, FR pants, FR overalls and FR jackets.
| Garment | Fabric and rating | Best for | Price (AUD) |
|---|---|---|---|
| Bisley Tecasafe Plus 580 Taped Hi Vis Lightweight FR Vented Shirt BS8098T | Inherent TenCate Tecasafe® Plus 580, Sto-nor 9801 FR tape, Class D/N | Pilbara summer, gas plant operators | $191.99 |
| Bisley Tecasafe Plus 700 Taped Hi Vis FR Shirt BS8081T | Inherent TenCate Tecasafe® Plus 700, heavier weight, radio and gas monitor loops | Processing plants, higher arc exposure | $196.99 |
| Bisley Women's Tecasafe Plus 580 Lightweight FR Shirt BL8097T | Inherent Tecasafe® Plus 580, women's fit, sizes 8 to 24 | Women on site who want a proper fit, not a scaled-down men's cut | $193.99 |
| Syzmik FR HRC2/PPE2 Spliced Shirt ZW140 | Modacrylic blend, HRC 2 (10 cal) at 250 gsm, hoop taped | Crews that need PPE 2 in a lightweight shirt | $140.99 |
| Syzmik FR HRC1/PPE1 Closed Front Shirt ZW133 | 93% meta-aramid, 5% para-aramid, 2% anti-static, closed front | Hydrocarbon and gas sites where closed fronts are mandatory | $157.99 |
| DNC Patron Saint FR Drill Shirt 3402 | Treated cotton drill, HRC 1 / PPE 1 | Budget FR for contractors and short-term crews | $59.99 |
| DNC Patron Saint FR Arc Rated Coverall 3427 | Treated cotton drill, HRC 2 / PPE 2, 3M FR tape | Shutdown and maintenance crews | $188.99 |
| Syzmik FR HRC2/PPE2 Spliced Overall ZC525 | Modacrylic blend, HRC 2, 250 gsm | Offshore and plant operators who want one-piece PPE 2 | $255.99 |
| Bisley Tecasafe Plus 700 Taped FR Pant BP8090T | Inherent Tecasafe® Plus 700, FR tape on upper leg | Matches the BS8081T shirt for a full inherent FR set | $176.99 |
| Bisley FR Taped Denim Jean BP8091T | Inherent FR denim, Sto-nor 9801 hoop tape | Fitters and operators who prefer a jean cut | $151.99 |
| Syzmik FR Arc Rated Anti-Static Waterproof Jacket ZJ900 | 300D Oxford with carbon fibre, FR arc rated finish, seam sealed | Wet season in the north-west, night shift | $255.99 |
| DNC Patron Saint FR Drill Welder's Jacket 3431 | Treated cotton drill, HRC 2 / PPE 2 | Boilermakers and hot work permits | $122.99 |
Prices are as listed on 14 October 2026 and exclude embroidery. Most of these are stocked in Perth for fast turnaround on crew orders, and we can embroider garments you already own.
Common questions
Can you embroider FR workwear I bought elsewhere? Yes. Bring in your Bisley, Syzmik, DNC, Hard Yakka or KingGee FR garments and we embroider them with the same FR thread, bobbin and backing. We check the care label first to confirm the garment is FR.
Does embroidery void the FR rating? Standard polyester embroidery is treated as voiding it by most site specifications. FR embroidery with aramid thread, aramid bobbin and Kevlar backing uses components tested to the same flame-spread standards as the garment, so the garment keeps its protection level. No embroiderer can re-certify a garment, but we give you a written statement of the components used.
What is the difference between HRC 1 and HRC 2? HRC (hazard risk category) comes from NFPA 70E and is now called PPE category. HRC 1 / PPE 1 is an arc rating of at least 4 cal/cm². HRC 2 / PPE 2 is at least 8 cal/cm². Your site's arc flash study tells you which category each task needs.
Can you do FR embroidery on hi-vis? Yes. All the shirts above are hi-vis FR. We place the logo so the garment keeps its AS/NZS 4602.1 Class D/N compliance and never stitch across the reflective tape.
How many colours are available in FR thread? Madeira Fire Fighter comes in 24 to 30 solid colours matched to Madeira Polyneon shades, which gives a close Pantone match for most company logos. Metallics and neons are not available in FR thread. Please note that we do not carry all the colours and only carry common colours such as black, white, red and a select few due to the cost of the threads and also low demand.
Is FR embroidery more expensive? Yes, by a small margin per garment. Aramid thread costs several times what polyester does and runs slower on the machine. On a $150 to $250 garment the difference is minor compared with the cost of a rejected crew at site induction.
Can you screen print or heat press on FR garments instead? We do not recommend it. Plastisol inks and heat-transfer vinyl are thermoplastic and will melt in a flash fire. Embroidery with aramid thread is the only branding method we put on FR workwear.
Do you supply FR workwear in Perth? Yes. Flash Uniforms is Perth based and stocks FR shirts, pants, overalls and jackets for same-week turnaround on crew orders. See our Hi Vis Workwear Perth range for non-FR hi-vis as well. Besides Perth we can ship FR workwear all over Australia for a flat rate shipping fee of only $14.95.
Get your crew's FR workwear branded properly
Email us your logo and the garments or styles SKU codes that you need, and we will come back with a digitised artwork FR proof, a colour match from the Fire Fighter range and what thread option are available and a per-garment price or a full quote including regular bulk ordering. Call us on 08 9240 1600 or email admin@flashuniforms.com.au, or start from the Fire Retardant Clothing collection and add FR embroidery at checkout.