Working in the cold can be brutal. Luckily if you know how to dress for work in the cold, it can be much more bearable. In this video I give you my three levels of dressing for the cold.
The coldest I’ve ever been on the job was inside a parking garage, hanging rigid pipe in February. I swear it was colder inside than outside, and with the wind whipping through it was well below zero.
Luckily I had learned how to dress for the cold years earlier while working as a chairlift operator, and those techniques not only saved my ass, but my fingers and toes as well.
Level 1
This is typically what I’ll wear when it’s around 30 degrees Fahrenheit. At that temperature I’ll likely be generating enough body heat through exertion that sweat becomes a problem. You know how you feel a chill when you get out of a pool even in the dead of summer? The same goes for moisture on your skin in the cold. Its simple energy transfer, and it’s the number one obstacle to keeping warm.
Base Layer
To manage this, I’ll wear a merino wool base layer. These have become much more affordable over the years, and their main function is to wick away sweat. They should fit tight against the body, you want as much surface contact as possible. I prefer a mock neck like this Helly Hansen model since you can open it up if you get hot. You can find these from any number of companies now, but I’d just suggest avoiding cotton as a base layer. Wool- fine, wool/synthetic blends- fine, just keep cotton off your skin if possible.
Heavyweight baselayer for those colder times of year.
Insulating Layer
On top of that I’ll wear a flannel shirt. It doesn’t really matter which one, I like my old Duluth Trading models but my favorite is still the Patagonia Farrier’s shirt. This is part of your insulating layer, and often what I strip down to when really exerting a lot of energy.
Expensive? Yes. Unparalleled? Also yes.
Shell Layer
Next is your work jacket of choice. Something with some decent insulation and abrasion resistance is preferable.
Carhartt vs. Dickies Who makes the best work jacket?
Engineered For high warmth in severely cold conditions.
Pants
For pants at this level I just stick with a good heavy duck canvas. Mostly these are cotton, but typically they work just fine in keeping you warm. At least I can still wear a tool belt and mobility isn’t compromised.
Socks and Boots
For socks I like the hunting socks from Darn Tough, and just my trusty Nick’s Builderpros, or Tanker Boots that I’ve been wearing recently. Make sure to keep within the safety regulations of the job you’re on or the trade you’re in.
Merino wool lightweight work sock.
The boot that changed my whole perception of how great work boots can be.
Gloves
The Maxi-Flex gloves or something similar work well, and they allow dexterity while offering a little (not much) insulation. These are usually issued by the company you work for, and only last a couple of days depending on the work you’re doing. Honestly I don’t really wear them much.
Level 2
When the forecast calls for 5-20 degrees, things get kicked up a notch. When I started out running a chairlift for a second job (and free ski time), I’d wear a long sleeve cotton tee shirt, cotton sweatshirt, sweatpants, and my nylon ski shell. At the end of each shift I was frozen. It wasn’t until a guy from the ski patrol showed me how to layer properly that I understood how to dress for the cold in a way that kept me safe and comfortable.
Base Layer
I’ll usually stick with the same base layer, and while it might be tempting to go with the cheaper 100% synthetic models, I’ve found they hold onto odor a lot more than wool or wool blends. They do tend to wick better, but even after washing them it’s not long before they start to smell again.
Insulating Layer
Here is where we need to start paying more attention to the middle layer- the insulating layer. The idea is to trap as much warm air as possible. High pile fleece works well, or even a lightweight down layer. I like the Gilliam vest from Carhartt, but you can find something similar pretty much anywhere – REI, Tractor Supply, etc. The problem is that they tend to snag and rip easily. That may not be a problem for you depending on the job, but for me- walking between metal studs, dealing with metal-clad cable, it’s a concern.
Shell Layer
I’ll often stick with the same insulated work jacket, and lately it’s been the Chief jacket from Heat Straps. Of course it entirely depends on the conditions you’re working in. I’ve found that a nylon shell work jacket is best when working near the ocean. We’re doing a job right now in Groton which is literally right on the shore, and the moisture makes the air feel much colder.
Pants
For pants I like the fleece or flannel lined models. You don’t have all the layers of long johns, which make it a pain in the neck to pee, and I don’t want to spend any more time in that port-a-let than I have to. This is also the temperature where insulated bibs work well, and the nice thing is that you can toss them on over whatever you’re wearing, so a lot of guys (including me) keep them in their vehicle.
Designed to block wind and keep you warm on those colder days on the job.
Socks and Boots
Boots stay the same but I’ll add in an alpaca wool insole and use a thicker sock. A key to keeping your feet warm is blood circulation, so make sure you’re not tying your boots too tight.
Another thing I hear on site is guys wearing two pairs of socks. This also can restrict blood flow, so I’d suggest just wearing one pair of good, thick socks. I like the bison wool ones from United by Blue, and there is another company I want to try called Vintage Bison USA. If your feet tend to get cold, bring a second pair of socks and swap them out at lunchtime. It makes a big difference.
Hat and Gloves
The standard issue hardhat liner comes out when it gets cold, and some safety guys will bust your stones if you wear a regular beanie under a hard hat. The liners are also nice because they cover your neck and often can tuck into the collar of your jacket. A lot of times these are free too, I know we order them by the sleeve for our guys.
Some thicker gloves with some grip work well at this temperature, though the rubber tends to get cold quickly. It’s still better than handling cold steel with nothing at all though.
Level 3
This is the level for the coldest days, night shifts, or when the wind is really whipping. In 2019 I was working night shift on the railroad in New York and learned first-hand how much colder the nights are. Wind came howling down the tracks, and inside a tunnel it can be absolutely miserable.
Base Layer
The warmest base layer material is silk. It’s expensive and it doesn’t wick as well as wool, but it’s warm. Top and bottoms are best if you can afford the set. In a pinch, you can use your wife’s Victoria’s Secret stuff. Just kidding, don’t do that. Unless it’s your thing. No judgement.
Silk is lightweight and one of nature’s best insulators.
Insulating Layer
The insulating layer can be a combination of high pile fleece, lightweight down, or even a thicker wool like the Snowcrest shirt from Duckworth. On top of that I’ve used a battery heated Milwaukee jacket. These are effective, but less so than I expected. They take off the chill, but it’s not like you’re sitting next to a wood stove or something. Plus they’re not meant for layering, but I’ll use it when it’s really windy or when working near the water.
Shell Layer
The big guns come out for a jacket, I love the Carhartt Yukon Extremes Parka. I used to wear a North Face, but it’s really not meant for jobsite abuse. Duluth Trading also makes a parka, and it looks to be pretty similar. A parka has some drawbacks though. You can forget wearing a tool belt- these are too long. They also don’t play nicely with fall protection harnesses due to their length. So in a case like that I’ll wear a pair of insulated coveralls. These aren’t as warm as the parka, but what they give up in comfort, they make up for in mobility. Plus you can always wear another jacket over them if needed. The big problem with coveralls is if that burrito you had for lunch isn’t agreeing with you, the whole top has to come down to use the bathroom. I told you not to buy lunch off the roach coach!
The Warmest Carhartt Jackets for 2024!
Carhartt Yukon Extremes gear is engineered for ultimate performance in the coldest conditions. This insulated active jac fights off cold, wind, and light rain so you can work through whatever weather comes your way.
There’s also a brand called Refrigerwear that specializes in cold weather gear. I have their High Vis Extreme Softshell Jacket, and it’s pretty decent. They say it’s good to -60 but I have a hard time believing that. HiVis Extreme Softshell Jacket.
When safety on the job in cold, miserable conditions is your everyday, you need the durable, extreme protection of our HiVis Extreme Softshell Jacket.
A good pair of insulated bibs pair nicely with a coat, just keep an eye on where the insulation begins on these. Sometimes only the legs are insulated while other times the entire chest panel is lined. In this case, more is more.
Socks and Boots
Regular work boots wont be ideal below zero no matter how many socks you wear. I’ll switch to the Baffin Apex boots, but I think their newest model is the Eiger boot. They have a removable insert which allows you to dry them out at the end of the day. Socks should be wool, and there are even sock liners which work just like your base layer to wick away sweat.
Hoffman also makes a great winter packer boot if you want something that’s more waterproof. Refrigerwear also has a pretty good selection of cold weather boots, so they’re worth checking out. Again, check your jobs safety requirements.
Hat and Gloves
If you can get away with it, mittens are better than gloves. There are hybrids which make you look like a lobster if you need a little more dexterity, but keeping your fingers together really helps keep them warm. Of course, this means that you’re limited on what tasks you can do. So if you need dexterity then mittens won’t be your best bet.
Along with a hardhat liner, I’ll use a balaclava for more coverage, but these tend to ice up due to the moisture in your breath. There are extreme models with valves in them, but I’ve never actually tried one. The Stormy Kromer bandana also works well, and I’ve found that sometimes using them in conjunction with each other can work well.
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