This article describes the basic evaluation process and test methodolo
gy employed when temperature extremes for clothing systems must be con
sidered as part of the U.S. Army's Health Hazard Assessment for materi
al in the development and acquisition process. The goals of the evalua
tion are to select clothing systems that minimize the hazards of heat
strain and to predict the heat strain for persons wearing such clothin
g. Clothing evaluations begin with biophysical assessments that determ
ine the thermal characteristics (vapor permeability and insulation) fo
r textiles via guarded hot plate tests and for clothing systems via th
ermal manikin tests. The results from biophysical tests can be used to
select the textile and/or clothing with the best thermal characterist
ics. The data from manikin evaluations also can be used in prediction
modeling. Human physiological testing is best done in a controlled lab
oratory environment, although for realism and user acceptability field
trials may also be conducted. Proven test and measurement methods mus
t be employed, and tests must control for confounding variables; subje
cts serve as their own controls, and test environment and procedures a
re consistent between trials. The process and test methodology describ
ed can be applied to the evaluation of civilian clothing systems as we
ll as to the military systems for which they were developed.