The Challenges of Bringing Stretch to FR Denim
Product developers must consider the variation of stretch, standards, partnerships and laundering.
- By Chris Romansky
- Mar 01, 2023
For many Americans, wearing jeans to work is the ultimate business casual. For workers in the oil & gas and electrical utilities industries, however, simply convincing supervisors that jeans are more comfortable than traditional workwear doesn’t cut it. Just like any PPE, flame-resistant (FR) denim must uphold industry standards and ensure that above all else, workers are protected from the everyday hazards on the job.
With those considerations in place, denim in these industries wasn’t always the go-to choice. FR denim was first introduced to the industry more than 25 years ago, but like most innovations, those first renditions of FR denim left a few characteristics to be desired.
For years, FR denim options were stiff, heavy and difficult to move in, especially in hot climates. But in the early 2010s, as workers demanded more fashion-forward apparel choices in their workwear, the industry was forced to address the comfort and style challenges of applying FR technology to denim apparel. Although color was the major initial request—wanting options that more closely imitated vintage washes or were available in lighter hues—stretch quickly became a priority for FR workwear.
Applying more stretch to FR-engineered denim is a bigger challenge than many workers and safety managers may understand. To grasp the innovation and technological know-how needed to excel at FR denim, it’s important to acknowledge four key considerations during product development.
The Difference Between Mechanical Stretch and Power Stretch
When considering how to add stretch to denim, product developers choose between two variations: mechanical stretch and power stretch. Mechanical stretch happens when the manufacturer takes a fabric without any stretch component and through the weaving process, gives the yarns some natural elasticity and in turn, the finished garment is more flexible. Typically with this process, manufacturers expect to see around a six to eight percent stretch percentage.
Additionally, power stretch denim includes some type of stretch component, like Lycra or Spandex, that gives the fabric the power of stretch. These stretch percentages can get manufacturers closer to the 12 to 14 percent range, which is more noticeable to end users. In some cases, more than 15 percent stretch can be achieved based on technological advancements in the space.
This article originally appeared in the March 1, 2023 issue of Occupational Health & Safety.