Tough guys (and gals) need tough duds. They need work clothes and work boots made specifically for real working people, like Carhartt overalls that are as rough-and-ready now as they were when railroad workers wore them in 1889. They need lugged, steel-toed leather work boots of the sort that Carolina Shoes makes for men who walk the high beams or drive the ‘dozers.
Today’s workwear is worn by every rugged type from longshoreman to lumberjack, cowpoke to construction worker. Workwear is about durability first, comfort second, and looks least of all. Yet work clothes and footwear have gained quite the following among the fashion crowd… perhaps because of the rugged styling and utility of this type of apparel.
A few big names immediately come to mind when you think about workwear: Carhartt, Tough Duck, Moose Creek, Carolina Shoes, Caterpillar. The one thing all these workwear brands have in common is that their products are incredibly durable. What they lack in frills they make up for in long-lasting, dependable protection. Read on to discover why work clothes are meaner than the rest, and what to look for when shopping for the clothing and boots you need for outdoor work.
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Materials for Work Clothing
Even though work clothes are ultra-rugged, they are designed to be fairly inexpensive and essentially disposable. They may not offer "performance fabrics" in the accepted sense, but work clothes are built much burlier than their expensive, lightweight counterparts.
Cotton Duck
By far the most popular workwear fabric, cotton duck is a weighty, plain-but-strong woven canvas. Despite its name, this hardy workwear fabric has nothing to do with waterfowl or their feathers. The term "duck" comes from the Dutch word doek, which refers to a linen canvas once used for sailors’ white trousers and outerwear. The word "cotton" has been added to modern duck items simply to distinguish them from traditional linen duck. Interestingly enough, though, cotton duck is related to another type of work-ready duck. Duct tape, often called "duck tape," was originally manufactured by adding an adhesive backing to regular cotton duck.
You’ve heard the expression "tougher than nails." Well, cotton duck may be "tougher than sails." The same general type of canvas duck used for many work clothes has often been used for traditional boat sails, since the thick cotton weave is incredibly resistant to tearing and rough wear. This workwear fabric is also found in four-walled tents, shoes and sand bags. Usually offered in drab colors like unbleached white, tan, and shades of brown or green, cotton duck work clothes never look very dirty even when they are.
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The advantages of cotton duck workwear fabric are many. For example:
- It has a relatively smooth surface that isn’t prone to snagging and tearing.
- It is probably second only to leather in the class of true workwear fabrics in its ability to block the wind (which can be more important than anything on a blustery winter jobsite).
- It is somewhat burn-resistant, albeit still certainly flammable. If you’re sleeping by a campfire or welding in the shop, a few small sparks or hot ashes won’t ruin the fabric, unlike nylon or other synthetics that end up with tiny pinholes everywhere in the same situation.
- It may feel stiff and uncomfortable at first, but after being washed and worn a few times should feel quite comfortable.
Cotton duck is classified by weight, with a heavier weight being thicker and more durable. "Numbered duck" refers to lighter duck fabrics found in work clothes, bags and boat covers (as opposed to "naught duck," which is a very heavy fabric). Numbered duck can be ranked from 1 to about 12, with 1 being heaviest and thickest and 12 the thinnest you’ll find. The grade of numbered duck refers to the number of ounces subtracted from 19 for a 36 by 22-inch piece of the fabric. For example, a piece of #8 numbered duck with dimensions of 36x22" weighs 11 ounces (19 – 8 = 11).
Here’s a table of numbered duck weights (notice that grades 7, 9 and 11 are missing; this is because they are no longer produced):
| Cotton Duck Fabric Weight Table |
| Numbered Duck Grade |
Fabric Weight (36x22") |
Common Uses |
| #12 |
7 oz. |
Light Clothes |
| #10 |
9 oz. |
Work Clothes, Shower Curtains |
| #8 |
11 oz. |
Work Clothes, Clothes Bags |
| #6 |
13 oz. |
Boat Covers, Heavy Work Clothes |
| #5 |
14 oz. |
Heavy Work Clothes |
| #4 |
15 oz. |
Sea Bags |
| #3 |
16 oz. |
Heavy-Duty Bags |
| #2 |
17 oz. |
Hatch Paulins |
| #1 |
18 oz. |
Sandbags, Cots, Hammocks |
Denim
Denim, the fabric most commonly associated with blue jeans and jean jackets, is a great workwear fabric for work clothes worn on and off the job. A rugged cotton twill fabric, it is recognized by the diagonal ribbing on the surface. Denim is less durable than duck, but generally more comfortable to wear and definitely more popular in after-work settings.
Flannel
Flannel is a light or medium-weight woven cloth, almost always 100% cotton. It is most often used to make long-sleeved work shirts and bedsheets and is distinguished by its softly brushed surface. Flannel work shirts have long been the cold-weather favorites of woodsmen and construction workers, because they are very warm, comfortable and relatively inexpensive.
Leather
Leather can be defined as the tanned hide of virtually any animal. It is used to make virtually every type of workwear accessory or work footwear, like work gloves, work boots, belts and jackets. There is perhaps no other workwear fabric as durable, protective, pliable and readily available as leather. Specialty leathers like elkskin and deerskin are frequently used to make leather work gloves because of their incredible toughness and supple stretching properties. For more information about various types of leather, read our Guide to Leathers.
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Synthetics
Nylon, polyester and other synthetic fabrics were relatively uncommon in work clothes of the past. However, with technological advances these fabrics are becoming more popular in the workwear world. For example, Carhartt now offers an "extreme" line of work coveralls made of super-thick, incredibly durable Cordura® nylon with a polyurethane coating to block wind and water.
Ring-Spun Cotton
Ring-spun workwear garments are those in which the cotton fibers are twisted together very tightly prior to weaving or knitting the yarns into fabric, making each thread stronger and smoother than regular cotton threads.
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Workwear Insulated Linings
Hard work knows no season. Workwear manufacturers are aware of this, and that’s why they make so many products designed for working in cold, windy winter weather.
One of the most common features found in winter work clothes is an insulative lining. Here are a few lining types and a brief description of each:
-
Blanket linings/ Flannel linings are soft linings of cotton, wool or acrylic that provide moderate warmth to work clothes. They are usually recognized by a plaid or similar pattern.
- Quilted linings are usually made of a smooth piece of synthetic fabric, stitched in diamond-shaped patterns over an insulative fill like polyester or down.
- Fleece linings offer a layer of plush polyester fleece bonded to the inside of the work outerwear, and are great for insulating and pulling moisture away from your body. In work jackets with very thick fleece, the lining is sometimes referred to as a pile lining.
These lining types often show up in various combinations in work clothes, such as coats with fleece-lined bodies and quilted nylon sleeves.
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Workwear Features
Workwear isn’t known for having lots of bells and whistles, but features can still be important – especially when they have practical merit.
Heavy duty zippers like YKK® zippers can withstand much greater forces than less-expensive zippers, which is important since their strength is continuously tested on the job site.
Rivets and bar tacks are features that add extra strength to reinforce seams on work clothes that face a lot of stress and strain. Rivets are probably familiar to you – they appear on most blue jeans at the top ends of the front pockets. Bar tacks are made from a series of stitches that usually contrast the main fabric.
Water repellency or full waterproofing is sometimes offered in workwear and work boots. Truly waterproof items often have a Gore-Tex® or similar waterproof breathable membrane. Some leather products, especially work boots, also fight off the elements with sealed seams and a waterproof finish.
Triple stitching is just what it sounds like: there are three rows of stitches along every major seam, to reinforce them for durability in work clothes. And if one row blows out, you’ve still got two to spare.
Flame resistance is built into some newer workwear products, and is designed to prevent burns from flash fires or electric welding arcs.
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Workwear by Category
Work Jackets/ Work Coats
On the jobsite, your work outerwear is by far your most important type of clothing. Your work jacket or coat protects you from the elements and job hazards. Some key things to consider when looking for a work coat are:
- Tough fabrics and solid construction
- Ribknit cuffs for durability and warmth
- A drawstring waist to trap warmth
- A hood (for winter work)
Coveralls/ Overalls
Coveralls (or "work bibs") and overalls are synonymous with hard work. You only wear these puppies when you’re going to be working on the shop floor, kneeling on muddy ground, or pounding framing nails in a January wind. Most work overalls and coveralls are insulated for warmth and have reinforcements like triple stitching at the seams. Other features to look for in work coveralls and overalls:
- Two-way leg zippers that open to the waist so it’s easy to put them on and take them off with work boots on, and also easy to air out when you get too warm.
- Utility pockets, tool pockets and hammer loops that keep the tools you need close at hand.
- Internal storm cuffs that retain heat.
Work Pants/ Jeans
Work pants are usually made of either denim or canvas duck for durability, and have the same reinforcement features as other workwear (triple stitching, rivets, etc.). Many have traditional "five-pocket" jeans styling, with hand pockets, rear pockets and a coin pocket above the right front pocket. A few extras to look for in work pants are:
- Hammer loops
- Tool pockets
- Double Knees (an added fabric layer over the knees)
- Clean-out bottoms (open bottoms on double knees to clean out debris)
- Extra belt loops or wider belt loops to help support the added weight of tools
Often times for work pants and overalls, the weight of the fabric will simply be displayed as the weight (in ounces) of a 36x22" piece of the raw fabric (see fabric weight descriptions under Cotton Duck). Below is a table with our recommendations for the ideal duck weight for work pants:
|
Best Work Pants by Fabric Weight
|
| Fabric Weight (36x22") | Best Season for Use | Degree of Durability |
| 7-9-ounce | Summer | Moderate |
| 10-11-ounce | Spring/Fall | Moderately High |
| 12-13 ounces | Spring/Fall | Very High |
| 14-15-ounce | Winter, often lined | Extremely high |
Note: Lighter work pants may have a double front to keep the weight light without sacrificing too much durability
Carhartt Pant Fit Guide
As with most other pants, the only measures on work pants you need to be concerned with are the inseam, waist and leg opening. The inseam is measured from the crotch of the pants down one leg to the cuff, while the leg opening is the circumference of one leg at the cuff. Opt for a larger leg opening (about 17-20") to fit your pants over your work boots. A work pants’ general size is based on the waist circumference, in inches.
Vests
Work vests have always been the perfect layering item. You can wear them over a work shirt for moderately cool weather or under your work coat on very cold days. Almost all work vests are insulated and have large pockets. They also keep your arms free for more dexterity on the job.
Work Shirts
What makes a work shirt? These shirts come in a wide range of options like flannels, sweatshirts, T-shirts, and hoodies. Wear whatever works best for you. Just pick a work shirt or sweatshirt that is comfortable enough to wear against your skin, provides adequate warmth, and is not so expensive that it’s hard to replace. You may want to try a sweat-wicking work shirt made of synthetic fabrics like polyester, which manage moisture and help fight odor.
Shorts
Work shorts are a necessity for hot weather, especially for activities like roofing and landscaping. Expect the same materials and features seen in work pants.
Thermals
Thermals or long underwear are the best way to add a layer of warmth to work clothes in the winter. A base layer should effectively wick moisture as well as insulate, so cheap cotton thermals are a poor choice. Opt instead for polyester, wool or silk.
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Work Accessories
Work Gloves
We admit that calluses are cool, but some jobs absolutely demand the warmth or protection of work gloves. Most work gloves are crafted from a natural leather like elkskin or deerskin, or sewn from a tough cotton duck.
Hats
Depending on the conditions, the hat you wear to work must either provide optimal sun protection with a wide brim or adequate warmth with a thick knit.
Sunglasses
The best sunglasses for work are those that block sun and glare, plus never fall off your face. Look for these sunglass features for outdoor work:
- Brown or yellow lenses, which may enhance depth perception and maintain adequate brightness.
- Polarized lenses if you’re working on or near snow, water, asphalt or reflective materials to cut glare.
- Wraparound frames that hug your face.
- Grippy nose and ear pieces (usually rubber pads).
Note: Never substitute regular sunglasses for protective eyewear when using tools that demand adequate eye protection. Also, never wear sunglasses with glass lenses on a jobsite, as they can shatter.
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Men’s Big and Tall Work Clothing
For men with larger frames, Sierra Trading Post offers an entire Big and Tall clothing section. You can shop for workwear in this section, or by scanning each product category for items with the words "For Large Men" or "For Tall Men" in the title. All Big and Tall work clothing items should appear in both the Big and Tall section and the appropriate product category.
Boots
Work Boots
Some features common in a pair of work boots are steel toes, oil-resistant outsoles, waterproofing, and/ or a design that Meets AST and EH electrical hazard standards for construction-site work. Most work boots have a tough leather upper that’s designed to last, and a shock-absorbing midsole that cushions the bottom of your foot.
Note: Even though steel-toed work boots are great for protecting your toes from falling objects, don’t wear them unless you need them – they add weight and can make your feet colder in the wintertime.
Western Boots
Besides traditional work boots, another footwear option for outdoor work is a Western boot. Great on the ranch for obvious reasons like a shape designed for stirrups, these boots are truly built tough and will last as well as any work boot. Also, they offer a very different style that may suit your tastes better. Many of these boots now offer the high upper and styling of a Western boot, but with a more modern shock-absorbing midsole and non-slip, lugged rubber outsole.
Socks
Be sure to wear socks that wick moisture away from your feet, cushion underneath, and are built to last. After all, what is the point in having good work boots if your feet are sore all day because of cheap socks?
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