PurposeThis study aims to investigate the heat transfer mechanism of the uniforms used by people working in hot, humid and windy environments. Furthermore, the effectiveness of an opening structure added to the armpit of the uniforms in improving thermal comfort was comparatively examined.Design/methodology/approachA set of uniforms was tested with the opening at the armpit alternatively zipped or unzipped. Thermal manikin and human tests were performed in a climatic chamber simulating the specific environmental conditions, including wind speeds at four levels (0.15, 0.5, 2, 4 m/s) and relative humidities at two levels (50 and 85%). Static and dynamic thermal insulations of clothing (IT) were examined by the thermal manikin tests. The human bodies' thermal responses, including heart rates (HR), eardrum temperatures (Te), skin temperatures (Tsk) and subjective perceptions, were given by the human tests.FindingsSpecial mechanisms of heat transfer in the specific uniforms used in tropical monsoon climates were revealed. Reductions on IT were caused by the movement of the human body and the environmental wind, and the empirical equations would underestimate this reduction. The opening at the armpit was able to prompt more heat transfer under dynamic condition, with reducing the IT by 11.8%, lowering the mean Tsk by 0.92°C, and significantly improving the subjective perceptions (p < 0.05). The heat exhaustion was alleviated with lowering the Te by 0.32°C.Originality/valueThis study managed to improve the thermal performance of uniforms for workers under unforgiving conditions. The evaluation and design methods introduced by this study provided practical guidance for similar products with strict dress codes and cost control requirements based on the findings from thorough product tests and analysis.