Recent decades have seen significant advances in personal protective equipment (PPE), as well as machine and equipment safeguards, to increase casthouse operators’ safety. As we add more layers and equipment, the risk of heat-related illness increases. Unfortunately, this all too often leads to operators removing the clothing that was designed to protect them, thereby placing themselves more at risk for molten metal contact. In conjunction with this trend, experiments were performed on the dry and wet resistance to heat absorption and water permeability (breathability) of fabrics commonly used in PPE clothing. These results present the greatest ability today of increasing operator comfort.