I’ve Been Welding 20 Years — And I’ve Caught Fire More Than Once
As a welder for over 20 years, I’ve caught myself on fire more times than I care to admit.
Sometimes once a week.
Sometimes more.
Most of the time it’s quick — a spark lands, you slap it out, keep moving.
But sometimes it’s not.
And the older I get, the more I realize: a lot of those fires were preventable.
Why Cotton Shirts Catch Fire So Easily
Cotton is highly flammable.
When sparks land on untreated cotton:
- It ignites quickly
- It holds heat
- It continues burning even after the spark is gone
Unlike some synthetic fabrics that melt (which is dangerous in its own way), cotton burns.
If you’re welding and wearing standard cotton:
You are at risk.
Especially if:
- The fabric is worn thin
- It’s frayed
- It’s hanging loose
- It’s untucked
Denim Isn’t Automatically “Safe”
A lot of guys assume denim is safe because it’s thick.
Denim is usually cotton.
Thick cotton burns slower — but it still burns.
A $17 denim shirt is cheap.
A $15,000 hospital bill isn’t.
I learned this the hard way.
In 2017, I was drilling holes with a mag drill wearing an old, ratty denim shirt.
The drill bit caught my shirt tail and nearly ripped the whole thing off me.
Loose clothing + rotating machinery = disaster waiting to happen.
Tuck your shirt in.
Every time.
Flame-Resistant (FR) Clothing vs Regular Cotton
If you weld regularly, especially in tight spaces, overhead, or around flammable materials, FR clothing is worth the investment.
FR clothing is:
- Designed to resist ignition
- Self-extinguishing
- Built for high-heat environments
Is it more expensive?
Yes.
Is it worth it?
Absolutely.
Appearance, Pride, and Safety Go Together
This might sound unrelated, but it’s not.
When you show up looking sharp:
- Shirt tucked
- Clothes intact
- No frayed edges
- No dangling fabric
You’re signaling discipline.
Safety is detail.
Detail is discipline.
Discipline prevents injury.
Looking “cool” in a torn, untucked shirt isn’t cool when it gets pulled into machinery or catches a spark.
Other Welding Clothing Safety Tips
- Avoid frayed cuffs and loose threads
- Never weld in synthetic athletic shirts
- Button sleeves securely
- Avoid loose shirt tails
- Inspect clothing before every shift
Small details prevent major injuries.
What Happens If You Don’t Notice You’re On Fire?
You might smell it.
You might not.
Wind can carry the smell away.
You might be focused in the zone.
Fire doesn’t care.
You won’t burn to death instantly.
But burns on your torso, arms, or neck can change your life.
Final Thoughts
Most welding injuries are preventable.
Pay attention to detail.
Fix hazards before they hurt someone — even if it’s someone you don’t like.
It takes less energy to prevent an accident than to deal with one.
In the next few articles, I’ll break down:
- Best welding shirts
- FR gear comparisons
- Gloves and jackets
- What to look for in real-world PPE
Because safety isn’t optional.
It’s part of the trade.
“Frequently Asked Questions”
Can denim catch fire while welding?
Absolutely! Denim is made of cotton.
Is 100% cotton safe for welding?
No, cotton is flammable and can smolder without any signs.
What material should welders wear?
Denim with a jacket is recommended, or leather.
Are welding jackets necessary?
No but they are much safer than a denim shirt that’s worn-out!
About the Author
Jeromy is a welder with more than 20 years of experience in welding and construction. Through Welded Forge, he shares practical lessons from the trades to help workers build skill, confidence, and pride in their craft.
More From The Working Man’s Handbook
- FR Gear Explained
- Boots That Survive the Jobsite
- Tools Worth the Money
- The Code of a True Tradesman
- The First Year in the Trades
- Hard Hats Explained