Fire Stunts and PPE: Choosing the Right Fire-Resistant Clothing for Performers and Crew

ISA Students learning about Cold Gel prep and application for Fire Stunts

Fire stunts are among the most visually dramatic in the stunt world, and done right, they are designed to be very safe. With the correct preparation, performers shouldn’t even feel the heat or flames. However, this level of safety relies on the quality of the protective gear worn and strict adherence to safety protocols. Whether you're a performer or part of the crew, it’s essential to understand the key factors that make fire-resistant clothing effective and how to choose the best gear for your fire stunt kit.

Safety Beyond the Performer: Crew and Production Risks
While the spotlight often shines on the performers, fire stunts also pose significant risks to crew members and the production team. Safety doesn’t stop at the performer—it must extend to everyone on the set or stage. A well-coordinated approach is key, and cutting corners on safety gear for anyone involved can endanger lives, and the entire production.

With proper planning, fire stunts should look extreme but be entirely controlled, allowing the performer to stay cool and safe under the flames.

Lessons from Other Industries: Elevating Stunt Safety
The development of fire-resistant gear has been driven largely by industries outside of entertainment, such as motorsports and heavy industries like oil and gas. These fields have stringent safety standards due to the inherent dangers of working around fire, heat, and flammable materials.

For instance, in motorsports, drivers and pit crews face the constant threat of fuel fires. This has driven advancements in flame-resistant suits that balance protection with comfort and mobility—qualities that are crucial for stunt performers as well. Similarly, industries like welding and foundries rely on fire-resistant clothing to protect workers from molten metal and extreme heat, often leading to standards that exceed those seen in film production.

Stunt performers can benefit from this expertise by sourcing their personal protective equipment (PPE) from these highly regulated industries. The rigorous research and development behind these products ensure the highest standards of fire protection are met, keeping performers safe while creating spectacular on-screen moments.

Fire-Resistant Clothing vs. Fireproof Clothing: What’s the Difference?
It’s important to clarify that no clothing is truly "fireproof." Fire-resistant (FR) clothing is designed to resist ignition, self-extinguish, and prevent flames from spreading, but that doesn't mean it won't conduct heat, prevent liquids seeping through or make you invulnerable to fire.

The goal of FR gear is to extend the time a performer has before the fire reaches their skin or causes injury. Understanding the different types of fire-resistant materials and certifications can help you choose the best gear for your specific stunt.

Key Standards and Ratings for Fire-Resistant Clothing
When selecting fire-resistant gear, look for certifications that ensure the clothing has been tested and approved for use in the working environment. There are ways to put together suits and PPE without using standardised equipment but we don't recommend this.  Some of the most common standards include:

• EN 11612 – Protective Clothing Against Heat and Flame: A European standard that evaluates fabric performance when exposed to radiant, convective, and contact heat, as well as molten metal splashes.
• EN 11611 – Protective Clothing for Welding: This standard is specific to welding but offers important protections against heat, flames, and sparks that are also relevant for fire stunts.
• NFPA 2112 – Flame-Resistant Clothing for Protection Against Flash Fire: Commonly used in North America, this standard defines the performance of clothing designed to protect against flash fires.
• ISO 15025 – Protective Clothing Against Limited Flame Spread: This international standard assesses a fabric’s ability to resist flames, making it particularly relevant for fire stunts.

The Misconception of Arc Flash Ratings
ATPV (Arc Thermal Performance Value) ratings are sometimes misinterpreted as suitable for fire work, but these ratings are specific to electrical arc hazards, not open flames. While a strong ATPV rating might seem impressive, it doesn’t translate to protection in a fire stunt scenario.

Fire stunt performers should prioritize heat and flame resistance ratings (like EN 11612 or NFPA 2112) over electrical hazard ratings when selecting their gear.

Understanding the Right Materials for Fire Stunts
Selecting the right materials for your fire stunt gear is crucial to ensuring safety. These are commonly used materials:

• Aramid Fibres (e.g., Nomex, Kevlar): These fibers are inherently fire-resistant and will not melt or drip when exposed to flames. They are widely used in motorsports and firefighting.
• Wool: Natural wool is inherently fire-resistant and can be used as a base layer. However, performers must avoid wool blends that contain synthetic fibers like polyester or nylon, which can melt under heat and cause serious injury.
  
• Fire-Treated Cotton: We don't recommend cotton but it is used. While untreated cotton ignites easily, especially when thin or used dry, fire-retardant cotton is treated to resist flames and is used in fire-resistant PPE. A side issue with cotton is it's absorbency, which can lead to wetted cotton producing excess steam during burns, which can easily be trapped and pushed back into the performers PPE layers, shortening their window of safety while performing.  
  
  

Synthetics: What to Avoid
It’s crucial to avoid synthetic materials that will flare or melt when exposed to heat, such as untreated polyester or nylon. When these materials melt, they can stick to the skin, leading to severe burns or increased severity and more complex treatment.

However, not all synthetic materials are harmful—aramid fibers, such as Nomex and Kevlar, are synthetic yet extremely fire-resistant. The key is to ensure any synthetic clothing in your fire stunt kit is specifically designed to resist melting and withstand high temperatures.

Building Your Fire Stunt Kit: Key Considerations
When assembling your fire stunt kit, keep these points in mind:

• Material Composition: Ensure your gear is made from fire-resistant materials like aramid fibers or fire-treated cotton. Avoid anything with untreated synthetics that can melt.
• Certification: Check that your gear meets relevant safety standards such as EN 11612 or NFPA 2112 - this will be shown on the label. And always check both labels! For tops, the brand liable at the next isn't always the place to check, so look for a label by the waist which will list materials and specs.
• Layering Strategy: Use fire-resistant base layers to provide additional protection under your outerwear. Be very cautious of untreated cotton or wool blends that include synthetics, and that includes stitching and insert panels or linings. We recommend pure merino wool that doesn't use nylon stitching.
• Fit and Mobility: Your fire stunt clothing should fit snugly without restricting movement. Tight garments can help prevent flames from reaching the skin or heat trapping, but when layering up your PPE should also still allow good movement so you can perform effectively.
• Inspect Your Gear Regularly: PPE can degrade or be damaged over time, particularly after multiple exposures to flames or heat, and washing cycles. Regular inspections, and before any stunt, are essential to ensure your PPE remains effective.

Precision, Preparation, and Safety First!
Fire Stunts are designed to look dangerous, but with the right preparation, they should be entirely controlled and safe. The right gear, tested thoroughly and used in conjunction with industry best practices, allows performers to act out intense scenes without feeling the flames. Remember to stay up-to-date with the latest gear and certifications, test your equipment, and never cut corners when it comes to safety.