Winter Workwear: How to Stay Warm on Site in Winter

Written by the Tauro Workwear team, ex-tradesmen turned workwear trouser designers

Short answer: the best winter workwear is a layering system, not one heavy garment. Wear a wicking base layer (merino or synthetic) under normal work trousers, add an insulating mid layer up top, put waterproofs on only when it is actually wet, and keep hi-vis on the outside. Then sort your knees, socks and boots, because that is where the cold gets in.

Let us be upfront: we do not sell thermal or waterproof trousers. We are a small team of ex-tradesmen who design slim fit work trousers in Redditch, and we have done enough frozen January mornings on site to know how to stay warm on site in winter without overheating by ten o'clock. This is the system we use, with our kit only where it fits.

Why does layering beat one heavy lined trouser?

A fleece-lined or thermal work trouser gives you a fixed amount of warmth. That is great at 7am on a frosty scaffold. It is less great at 11am when you are digging out a footing, or when you go from the van into a customer's heated house to do second fix. You cannot take the lining out, so you sweat, the sweat sits in the fabric, and when you stop for dinner you get cold fast.

Layers let you adjust. Thermal leggings under a normal pair of work trousers give you most of the warmth of a lined trouser in the morning, and you can peel them off in the van at lunch if the day warms up. For trades that move between outside and inside, or between hard graft and standing about, that flexibility is the whole point.

To be fair to lined trousers, they make sense for some jobs. If you are stood still in the cold all day, as a banksman, traffic marshal or someone on a static checkpoint, a properly insulated trouser is a sensible buy. We just do not make one.

What should you wear under work trousers in winter?

A thin, close-fitting base layer that pulls sweat away from your skin. Merino wool and synthetics both do the job. Merino stays fresher for longer if you wear it for a few days; synthetics are usually cheaper. What you want to avoid next to the skin is cotton. As Cotswold Outdoor's layering guide puts it, "Cotton absorbs sweat and holds moisture, which can make you feel cold and uncomfortable."

In a slim fit trouser, go for a thin base layer rather than thick fleece-backed leggings. Our trousers are cut slim, not small, with room for a thin layer underneath. If you wear heavy thermals all winter, or you are between sizes, size up on the waist. The size guide has the measurements.

Winter workwear layering: what goes where

Layer	What to wear	Why	Avoid
Base, legs	Thin merino or synthetic leggings	Wicks sweat, adds warmth, comes off at lunch	Cotton long johns
Base, top	Merino or synthetic long-sleeve	Keeps sweat off your skin	Cotton t-shirt as the first layer
Trousers	Your normal stretch work trousers	Pockets, knee pads, holsters where you need them	Rigid trousers that bind over a base layer
Mid, top	Fleece, hoodie or softshell	Traps warmth, easy to take off	One huge coat with nothing under it
Outer	Waterproof jacket and overtrousers when wet	Keeps rain off everything else	Wearing waterproofs all day in the dry
Top of everything	Hi-vis where required	It only works if people can see it	A hoodie pulled over the vest

Are cotton-rich work trousers OK in winter?

Yes, as the outer layer over a wicking base layer, in the dry. Our Ranger is 98% cotton, 2% elastane, and it feels like a normal pair of trousers rather than a technical shell. The Rampage is 60% cotton, 38% polyester, 2% elastane. Both have Cordura on the knee pad pockets and back pockets, and stretch so they do not bind when you squat with a base layer on.

What they are not is waterproof or insulated, and we are not going to pretend otherwise. Cotton soaks up rain and holds it. So the rule is simple: cotton-rich trousers plus thermal leggings for cold, dry days, and waterproof overtrousers on top when it rains. That combination beats one heavy lined trouser for most electricians, plumbers, carpenters and anyone who spends part of the day indoors.

How do you keep your knees warm and dry when kneeling?

Knees go first in winter. Kneeling on a frozen slab, a wet screed or a frosty scaffold board pulls the heat straight out of you, and once the knee of your trousers is wet it stays wet all day.

• Wear knee pads every time you kneel. A foam pad puts a layer between your knee and the cold ground, as well as protecting the joint. Our knee pad pockets take standard inserts but are not EN 14404 certified. If your site requires certified protection, use a certified trouser and pad combination, because type 2 certification only counts when the right pads go in the right trousers.
• Use a kneeling mat for long spells. Laying a floor, setting kerbs or working on a drain run, a mat keeps you off the wet ground altogether.
• Put overtrousers on before you kneel in the wet, not after the knees are soaked.

What about boots and socks?

Cold feet will finish your day quicker than anything. A few rules we stick to:

• One good wool-rich work sock usually beats two thin cotton pairs. Doubling up can make your boots tight, and tight boots mean cold feet.
• Keep a spare pair of socks in the van. Changing into dry socks at dinner is the cheapest warmth you will ever buy.
• Dry your boots properly overnight, away from direct heat that can crack the leather.
• Check your boots are still waterproof before winter starts, not halfway through a wet week.

Where does hi-vis go when you are wearing layers?

On top, always. If your site requires hi-vis, it has to be the outermost layer and fully visible. Buy your hi-vis a size up so it goes over your jacket in January as well as your t-shirt in July. A hoodie pulled over a hi-vis vest defeats the point of wearing one. For your head, use a liner designed for your hard hat rather than a beanie squashed underneath.

When should you choose waterproof overtrousers?

When it is actually raining, or you are kneeling or working in wet ground. Waterproof workwear is rated under EN 343, which gives two numbers from 1 to 4: the first for resistance to water getting through, the second for breathability. Class 4 is the best for each. If you are out in rain all day, look for a high first number. If you are working hard in them, the breathability number matters too, or you will be wet from the inside.

Look for side zips long enough to get them on and off over your boots. Then take them off when the rain stops, because waterproofs worn in the dry trap sweat.

What should your employer provide in winter?

HSE's cold weather guidance says employers should make sure PPE is appropriate, provide appropriate protective clothing for cold environments, schedule more frequent rest breaks, and provide facilities for warming up and hot drinks. If you are on a big site and nobody has mentioned winter kit, it is worth asking.

When winter is over, look after your kit. Our workwear care guide covers washing and drying so your trousers last into next year. And if you want something that moves properly over a base layer, browse our slim fit work trousers.

Frequently asked questions

What should I wear under work trousers in winter?

A thin merino or synthetic base layer, such as thermal leggings. Both pull sweat away from your skin so you stay warm when you stop working. Avoid cotton long johns, because cotton absorbs sweat and holds moisture. In slim fit trousers, choose a thin layer rather than thick fleece-backed leggings, and size up on the waist if needed.

Are thermal lined work trousers worth it?

They are worth it if you stand still in the cold all day, such as a banksman or traffic marshal. For trades that move between outside and indoors, or between hard graft and standing, normal work trousers with thermal leggings underneath are often better, because you can take the base layer off when you warm up instead of sweating.

Can you wear thermals under slim fit work trousers?

Yes, as long as the thermals are thin and the trousers have stretch. Tauro trousers are cut slim, not small, with room for a thin base layer, and have 2% elastane so they do not bind when you squat. If you wear thick thermals all winter, or you are between sizes, go up a size on the waist.

What waterproof rating do I need for working outside?

Waterproof workwear is rated under EN 343 with two classes from 1 to 4. The first is resistance to water penetration and the second is breathability, with 4 the best for each. For all-day rain, look for a high first number. If you work hard in your waterproofs, a high breathability number stops you getting wet from sweat.

How do I stop my knees getting cold on site?

Wear knee pads every time you kneel, so there is a layer between your knee and the frozen or wet ground, and use a kneeling mat for long spells. Put waterproof overtrousers on before kneeling in the wet. If your site requires certified knee protection, use an EN 14404 certified trouser and pad combination.

Want to see how a pair layers over your thermals? Wear them on site. Our 30-day returns are a genuine wear test: worn and washed is fine, as long as they are not deliberately damaged, altered or missing the holsters. UK returns are free. See the returns details before you order.