Testing protective workwear: safety proven with DuPont™ Thermo-Man®

26 August 2025Workwear

How safe is your workwear?

In hazardous environments such as foundries, power installations or the metal industry, protective workwear is more than a requirement - it’s a life-saving necessity. At CWS Workwear, we don’t just supply garments that are certified - we go one step further by making sure they’re also proven to perform under extreme conditions.
That’s why we test our Nomex® protective clothing using one of the most advanced thermal evaluation systems available in the world: the DuPont™ Thermo-Man®.

What is Thermo-Man®?

Originally developed in the 1970s by the U.S. military and DuPont™, Thermo-Man® is a life-sized, high-tech manikin specifically engineered to test the performance of flame-resistant (FR) personal protective equipment.
The manikin is equipped with 122 heat sensors. These sensors measure the heat transfer on the manikin’s surface during a simulated flash fire, providing a detailed and data-driven look at how protective clothing behaves in real-life emergency conditions.

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How the test works

To ensure the highest level of protection, the DuPont™ Thermo-Man® system subjects protective garments to one of the most rigorous thermal evaluations in the industry. The life-sized, fully sensor-equipped manikin is dressed in in test garments—whether they are made of Nomex® or other flame-resistant fabrics—and prepared for extreme conditions.

Once suited up, the manikin is exposed to a sudden, high-intensity flash fire lasting approximately 4 seconds. This simulates a realistic industrial accident scenario, such as those that could occur in environments like oil refineries, chemical plants, or metal processing facilities. The flames can reach temperatures of up to 1,000°C (1,832°F), providing a true-to-life representation of a worst-case thermal event.

Thermo-Man® is equipped with over 100 heat sensors across its surface, allowing for precise measurement of heat transfer through the garment and prediction of potential burn injuries. This data is then analyzed to determine the effectiveness of the fabric and garment design in protecting the wearer from second- and third-degree burns.

By replicating these life-threatening situations under controlled conditions, Thermo-Man® helps manufacturers like CWS Workwear verify that their protective clothing not only meets standards but also offers reliable, proven protection in the most critical moments.

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Why this matters

The insights gathered from Thermo-Man® testing allow us to:
•    Validate the thermal resistance of Nomex® clothing under flash-fire conditions
•    Identify critical areas for design improvements, such as seam placement or fabric layering
•    Ensure our garments meet or exceed international safety standards
•    Provide end-users with a quantifiable safety report, reinforcing trust in the gear they wear

And because Nomex® garments offer inherent protection, their flame resistance doesn’t fade - even after repeated wear and washing. This means the results from Thermo-Man® aren’t just impressive in the lab - they reflect true, lasting protection in the field.
However, to maintain this level of protection, proper care is essential. That’s why Nomex® garments should not be washed at home. Only professional maintenance in an industrial laundry ensures the protective qualities remain intact - safeguarding wearers shift after shift.

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Proven in the lab. Trusted on the job.

With CWS Workwear, you’re not just outfitting your team — you’re protecting lives with clothing that’s tested, trusted, and built to perform under pressure.

Trust is built by testing. And we test to protect.

Want to learn more about our Nomex® collections or how Thermo-Man® data helps us continuously improve? Get in contact with us, our sales colleagues will be happy to share knowledge and information.