What does a simulated full-body flash fire actually look like? We recently got an inside look at how Flamesafe Workwear's FR fabrics handle extreme heat, courtesy of footage from AITEX's Research & Innovation Center in Spain.
Watch the video below to see the "Thermo Tex Test" in action, and read on to see exactly what's happening beneath the flames.
The test is a mannequin flash fire test, where fabrics are mounted on an instrumented mannequin and exposed to a ring of gas burners simulating a full-body flash fire.
What's actually happening in the test
A row of propane burners surrounds the mannequin on all sides. When the test begins, every burner ignites simultaneously, engulfing the fabrics in flame for a set exposure time. Sensors built into the mannequin measure heat transfer through the material across the body, calculating predicted burn injury based on how much thermal energy actually reaches "skin" level.
After the flames are extinguished, the fabric is assessed for:
- Afterflame time - does it keep burning once the ignition source is removed, or self-extinguish?
- Char length and damage - how much of the material is structurally compromised?
- Shrinkage and melting - does it melt onto the body (a major risk with non-FR synthetics) or hold its shape?
- Predicted body burn percentage - calculated from heat sensor data, this is the headline figure used against standards like NFPA 2112 and ASTM F1506.
Why this matters for the people wearing it
This isn't just about ticking a compliance box - it's about real-world survival. In the field, there's no second chance to find out if a fabric doesn't perform.
Next time you're choosing FR workwear, it's worth asking: has the fabric itself been through a test like this? With Flamesafe, the answer is always yes.
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