Workwear T-Shirt Materials Explained

A t-shirt is a t-shirt, right? Not so fast. While a shirt's fabric may seem like a minor detail, it's a huge deal for workers who are moving, sweating, and generally putting their tees through the wringer on a daily basis. They need a shirt that performs on the job and bounces back after numerous washings. This short article compares different workwear t-shirt fabrics so you have a better understanding of what to expect from each material on the job.

Workwear t-shirt fabrics generally fall in one of three buckets: 100% cotton, 100% polyester, or a cotton/poly blend. While you may not be keenly aware of the shirt fabric you prefer, each of these fabric types have unique characteristics that you most definitely see and feel when you wear them.

100% Cotton T-Shirts

To many, 100% cotton is the gold standard for shirt fabrics. Some of Carhartt's most iconic shirts, for example, are made from 100% cotton. It is a breathable, soft and sturdy fabric that rarely disappoints, but it does have a few drawbacks: Heavier cotton shirts lose their breathability and won't dry as quickly as the other fabrics outlined below. Cotton also has a tendency to wrinkle and tear easier than blended fabrics and polyester, making it less durable after repeated washes and wear.

Popular 100% Cotton T-Shirts

100% Polyester T-Shirts

Polyester is a petroleum-based synthetic fiber. It is tough, lightweight and less prone to wrinkles than cotton. Because its fibers are strong, this fabric won't wear out as quickly as cotton and holds its color, which is an important feature for shirts that'll endure repeated washings and abuse. That's why this fabric is a popular choice for work polos and hi-visibility garments. It's also less absorbent than cotton, making it less susceptible to stains. Like cotton, polyester has some disadvantages too. For starters, 100% polyester has a synthetic look and feel, meaning it doesn't appear as natural or feel as soft on the skin. In fact, some wearers with sensitive skin experience rashes with certain polyester fabrics. Static cling is another annoying byproduct of polyester fabric, not to mention this material can be very clingy when it's wet. Because it's essentially made from tiny plastic fibers, basic polyester is less breathable than cotton. However, many of the polyester fabrics used on workwear t-shirts feature a looser weave that allows moisture and air to flow more freely.

Popular 100% Polyester T-Shirts

Poly/Cotton Blend T-Shirts

Like its name suggests, this fabric is a blend of natural cotton and synthetic polyester. The most popular ratio on the market is 65% cotton and 35% polyester, although other combinations do exist. So, what's the advantage of a poly/cotton blend? Simply put, this fabric is designed to maximize the advantages of both cotton and polyester. That means a poly/cotton blend is breathable, but also lightweight. It will feel softer than 100% polyester, but won't wrinkle as easily as cotton. It's durable, but not clingy. Generally speaking, this fabric combination can endure more abuse and washings than 100% cotton, while retaining its color and shape. Carhartt's patented Force line features t-shirts made with a cotton/poly blend. These popular t-shirts dry fast, wick sweat and are great for work in warmer weather.

Popular Poly/Cotton T-Shirts

Workwear T-Shirt Fabrics Pros and Cons

Which material is right for you?

So, which fabric is the "right" fabric? All three materials have their strengths and weaknesses. The fabric you choose largely comes down to personal preference and the conditions you'll be working in. If ultimate breathability is the goal, then all-natural cotton is probably your best choice. If you need some additional durability and prefer a quick-drying material with a more athletic look and feel, then a poly-cotton or 100% polyester material may be your best bet.

Need more help picking a shirt?