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PROTECTIVE APPAREL Comfort equals compliance. products for multi-use environments has changed the way a lot of these safety directors make their decisions on what to wear in their specific location.” In essence, the top of the hazard pyramid requires not only higher protection levels but also a holistic approach, understand- ing the complex, multifaceted risks workers face and designing apparel to address them all. Emphasizing Comfort But it’s important to think about how that layering plays out in the real-world setting presented by these extreme environments. Using the example of safety protocols for workers in steel mills, a three-layer system is employed that involves a base layer, followed by a coverall, and finally, an aluminized outer layer. That’s a lot of coverage for a worker in a still mill, Hirschi notes. “No one wants to be wearing three layers when you’re stand- ing in front of a 3,000-degree furnace,” he says. Yet, the efficacy of these layers is undeniable. Those three layers will protect against an incident such as a molten metal splash. “There haven’t been any injuries reported when they’re compliant.” The key phrase in that sentence is “when they’re compliant,” Hirschi underscores. “Say you work in the south at a pulp paper mill,” he continues explaining, using another example where the layers might even be fewer. “It’s 100 percent humidity, 90 degrees outside, and you’re supposed to throw on multiple layers in front of a 2,000-degree furnace. It’s simply not feasible for someone to work long hours in that environment.” The key lies in making each layer as light as possible, ensuring that workers are more likely to wear them and remain safe in case of unforeseen accidents. “Comfort equals compliance is kind of what everyone says in the industry,” Hirschi explains. The mantra is simple, but it’s profound. The basic idea is that if the personal protective equipment (PPE) handed to a worker isn’t comfortable, there’s a good chance it will be modified, altered, or worse, left unworn. The result? Potential injuries and non-com- pliance with safety standards. Innovations for the Industrial Athlete Herein lies the need for innovation — to create protective apparel options that provide layered solutions for extreme environments that also feature multiple hazards and, at the same time, make it something workers will truly be able to wear. “The more comfortable you can make it, the better,” Hirschi says. “So, if you can innovate and create options that workers and safety managers can choose depending on what that hazard is, then that leads to greater protection and better compliance for onsite safety overall.” Developing fibers, materials and coatings that are lighter, more flflexible and moisture-wicking for workers’ protective layers is essential. ThThe sources for some of those innovations might be a little surprising. “Actually, we take a lot of cues from the outdoor industry and the activewear industry,” Hirschi explains. ThThose companies focus considerable attention on researching and developing clothing that has to deal with factors such as sun, rain and moisture management. And those athletic wear innovations perfectly align with how many workers see themselves: as industrial athletes. “They see what they’re doing as athletic as there are so many physical requirements,” he explains. “It’s grueling. You have to be in shape. You can’t just show up and hope to last through an eight- hour shift of sweat and through your clothes. You actually have to be able to manage that, and whatever apparel you’re wearing should complement that.” Striking Balances That said, Hirschi notes that the fibers and materials have to pro- tect against exposure to the hazards of the work environment. That can create a balancing act when it comes to product design. For example, a certain type of inherent non-flammability might be needed, but it doesn’t allow for moisture wicking. “The trade-off is you have to prioritize safety,” he explains, “but also get the apparel as lightweight or as flexible as possible to allow workers to be able to perform their job task for a longer and more effectively.” Another sporting realm that has helped drive protective ap- parel innovation that aims to strike that balance is motorsports. Mike Chapman, a race car driver, sought a material to insulate heat transfer within an engine. This quest led to the application of Oxidized Polyacrylonitrile (OPAN) fiber, a precursor to car- bon fiber. Blending these OPAN fibers with strengthening fibers produces a fabric that undergoes a carbonizing process when ex- posed to heat, which effectively absorbs the heat. Hirschi’s company, CarbonX started using the material to cre- ate much lighter protective apparel for extreme environments. Jack demonstrates the efficacy of his company’s material by apply- ing a 2000-degree butane torch to a glove woven with CarbonX. The weave is loose, and his skin is visible. The glove absorbs the heat and spreads it across its surface. Incorporated into outer jackets for environments like steel mills, CarbonX can get its material down to 10 ounces per square yard, which marks a significant weight savings against materials that pro- tect at the same level but at between 19 and 24 ounces a yard. At the same time, Hirschi acknowledges that innovations come at a cost. Gear that provides protection against multiple hazards in extreme environments and is lighter and easier to wear requires materials that will entail a higher price. But for jobs at the top of that pyramid, those capabilities can feel like a good bargain. “These are jobs that people have to do,” he emphasizes. “There’s no way around doing them. So, to make workers as safe as possible is the challenge. The best way to do that is to find ways to protect them that make them more comfortable and compliant when they do it. That’s the overall arc of where the innovations need to go.” David Kopf is the Publisher and Executive Editor of Occupational Health & Safety magazine. He can be reached at dkopf@1105media.com. 18 Occupational Health & Safety | OCTOBER 2023 www.ohsonline.com