How to dress for a world on fire

Right now, every time I check my news or social media feeds, it feels like the world is on fire. Last summer, it was California; now it's Australia. People are running from flames and choking on smoke across the developed world, and no matter where you live, you can't help but wonder if the fires will eventually reach your doorstep.

Even if you're sure you won’t face a brushfire, wildfire, or even a house fire, fire remains a critical part of many disaster scenarios. In areas without electricity, campfires and cooking fires are the norm. Throughout most of human history, before the rise of power grids, people were likely to smell like smoke on a daily basis.

I've been thinking a lot lately about how likely it is that I'll be around open flames in a crisis, and what that means for one of the most basic — yet often ignored — aspects of preparedness: clothing.

My recent deep dives into advanced fabrics and technical coatings during our tarp and paracord reviews have reinforced something I already knew from personal experience: synthetics and open flame don't mix well.

The Problem with Fire and Synthetics

There's a reason firefighters call synthetic base layers "shrink wrap." Unlike natural fibers like wool, cotton, or hemp, synthetics don't burn to harmless ash. Instead, they melt and drip, often causing severe burns when they come into contact with skin.

You don’t have to look far to find stories of gear being damaged by flying embers from campfires. I’ve had enough synthetic shirts with pinholes from grilling to always be cautious about what I wear when handling a Big Green Egg.

Video from one of our tests showing how nylon and polyester strands melt and burn:

Holes in clothing, tarps, packs, tents, and bedding from stray embers are common because synthetics like nylon and polyester react poorly to open flames and sparks. Nylon melts at as low as 370°F, turning into a hot, molten wax that’s dangerous on skin. Polyester also melts and burns, producing thick black smoke.

If you’re using synthetic materials, you need to be extra careful to avoid sparks. But even then, your precautions may fail, and your gear will eventually get damaged.

This is a big issue for preppers, because one of our main priorities at The Prepared is recommending gear that's durable and forgiving. People in emergencies often make mistakes, and we want gear that can handle that. But with synthetics, there's almost no margin for error when it comes to fire. That’s why I'm starting to think about traditional materials like wool, leather, and waxed cotton — especially for backup or bug-in scenarios.

Revisiting Natural Fibers

The realization that synthetics might not hold up in a major grid-down situation has changed how I approach clothing and preparedness. I’ve started researching and experimenting with natural fibers, and even adjusted my daily wardrobe to include more traditional materials — everything from buffalo wool and alpaca to waxed canvas and cashmere.

I’ll be sharing more of what I’ve learned in future posts — product recommendations, testing, and reviews — but here are a few reasons to consider incorporating more natural materials into your wardrobe:

  • Cotton canvas can handle embers well, especially when waxed. A tight weave makes it less likely to catch fire.
  • Waxed cotton is incredibly durable, resistant to abrasion and punctures, and lasts for decades. It also offers some water resistance.
  • Unwaxed cotton is tough and long-lasting. You can easily waterproof it with a poncho or wax it with a heat gun.
  • Natural fabrics are easier to repair in the field with a simple sewing kit.
  • Wool is naturally flame-resistant and self-extinguishes when the heat source is removed.
  • Wool/nylon blends can retain some flame resistance if the nylon content is low (around 20% or less).

Watch this video for a quick demonstration of wool's flame resistance.

Of course, natural fibers aren’t perfect. They come with their own risks — like the old saying “cotton kills” when wet. Modern synthetics still offer advantages in weight, comfort, and versatility. But I’m learning more every day, and I’ll keep sharing my findings as I go.

I’ve actually bought a bunch of products — outerwear, base layers, waterproofing supplies, and more — all on my own, and I plan to write about them in the coming weeks. Even on New Year’s Day, I spent the morning waxing a pair of denim/Dyneema cargo pants I got on Black Friday. So stay tuned — and feel free to leave comments or suggest gear ideas below!

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