Amelia Griffiths

Jan 23, 2024

Best Thermal Overalls of 2024: Keeping You Warm in the Coldest Conditions - A Comprehensive Review

Five of the best thermal overalls reviewed by the Workwear Gurus

Choosing the right thermal overalls in 2024 is more than a matter of preference; it's about finding the perfect blend of warmth, comfort, and functionality. With a myriad of options available, selecting thermal overalls requires careful consideration of various factors such as insulation quality, waterproofing, and breathability. At Workwear Gurus, we understand the significance of staying warm and protected in harsh conditions. Combining our industry expertise with real customer feedback, we have curated a list of some of the most popular and favored thermal overalls available on our website. Our aim is to guide you through these options, highlighting unique features that make each pair a worthy choice for battling the cold.

What's covered in this review?

  • Introduction
  • Blaklader 6785 Workwear Winter Overalls - Mens (67851977)
  • Mascot Ventura Winter Boilersuit Overall 14119-194 - Industry, Mens
  • Portwest S816 Orkney Lined Coveralls
  • Helly Hansen Alna 2.0 Hi Vis Insulated Winter Overalls Suit - 71694
  • PULSAR G100COV Thinsulate Coverall Liner
  • Our recommendation

Top 5 Best Thermal Overalls

Blaklader 6785 Workwear Winter Overalls - Mens (67851977)

Blaklader's 6785 Workwear Winter Overalls are a testament to advanced thermal technology and design. Engineered with 100% polyester, oxford laminated fabric, these overalls are both waterproof and breathable, ensuring optimal comfort in cold and wet conditions. The stretch panel in the back and ventilation under the sleeves enhance mobility and air circulation, while the fleece-lined collar and removable hood provide additional warmth and flexibility.

What we liked:
-Excellent waterproof and breathability features.
-Enhanced mobility with stretch panels and ventilation.
-Removable hood and fleece-lined collar for extra warmth.
-Reflective details for visibility and safety.

Our verdict:
Blaklader 6785 is an outstanding choice for professionals who need reliable warmth and mobility in extreme conditions.

View All Blaklader Overalls


Mascot Ventura Winter Boilersuit Overall 14119-194 - Industry, Mens

The Mascot Ventura Winter Boilersuit offers a robust solution for thermal protection. Its breathable, wind and waterproof fabric, along with taped seams, ensure a dry and comfortable experience. The detachable lined hood and adjustable kneepad pockets provide versatility and convenience, while the stretch fabric at the back allows for freedom of movement. The added reflectors enhance visibility in low-light conditions.

What we liked:
-Superior waterproof and windproof capabilities.
-Detachable hood and adjustable kneepads for customization.
-Stretch fabric at the back for added mobility.
-Reflective elements for increased visibility.

Our verdict:
This boilersuit is perfect for those who require a high level of thermal protection without sacrificing comfort and mobility.

View All Mascot Overalls


Portwest S816 Orkney Lined Coveralls

Portwest S816 Orkney Lined Coveralls are designed for ultimate warmth and comfort. The lining adds substantial warmth, ideal for extreme cold conditions, and the fabric’s UPF rating provides protection against UV rays. The half-elasticated waist and action back ensure a secure and comfortable fit, while the numerous pockets, including a phone and sleeve pocket, offer practical storage. Its certification for protection against cold up to -40°C is particularly impressive.

What we liked:
-Exceptional lining for added warmth.
-UPF rated fabric for UV protection.
-Comfortable fit with elasticated waist and action back.
-Ample storage with 8 pockets.

Our verdict:
These coveralls are a great choice for those working in extremely cold environments, providing both warmth and functionality.

View All Portwest Overalls


Helly Hansen Alna 2.0 Hi Vis Insulated Winter Overalls Suit - 71694

The Helly Hansen Alna 2.0 is a top-tier choice for thermal overalls. It offers a fully wind and waterproof experience with a fully taped construction. The Life Pocket™ feature is innovative, designed to extend the life of electronic devices in cold conditions. The detachable hood, adjustable cuffs, and knee-high boot zipper enhance functionality and comfort, while the Hi Vis certification ensures visibility in hazardous environments.

What we liked:
-Wind and waterproof with fully taped construction.
-Innovative Life Pocket™ for electronic devices.
-High visibility for safety in hazardous conditions.
-Functional features like detachable hood and adjustable cuffs.

Our verdict:
Ideal for those who require the highest level of thermal protection along with safety features in hazardous work environments.


PULSAR G100COV Thinsulate Coverall Liner

The PULSAR G100COV Thinsulate Overall Liner is an excellent addition to any foul weather gear. Its 3M™ Thinsulate Insulation provides maximum heat retention, crucial in extremely cold conditions. The YKK zips ensure easy integration with compatible coveralls, while the anchorage fastening points offer a precise fit. The knitted cotton cuffs and ankles add an extra layer of comfort and warmth.

What we liked:
-Superior heat retention with 3M™ Thinsulate Insulation.
-Easy integration with compatible coveralls.
-Precise fit with anchorage fastening points.
-Additional comfort with knitted cotton cuffs and ankles.

Our verdict:
This liner is a superb choice for those needing an extra layer of warmth in their existing foul weather gear, especially in extreme conditions.

View All Pulsar Overalls



The thermal overalls of 2024 offer a range of options to suit various harsh working conditions. From the waterproof and breathable Blaklader 6785 to the innovative Helly Hansen Alna 2.0 with its Life Pocket™ feature, each product stands out for its unique capabilities in keeping you warm and protected. The Portwest S816 and Mascot Ventura provide exceptional comfort and functionality, while the PULSAR G100COV liner adds an essential layer of warmth. These products represent some of the best thermal overalls available, making them excellent choices for those seeking reliable cold-weather workwear.

People Also Read

Have Any Questions?

We are here to answer all of your queries

Follow us on social media