The US Army is interested in a flame-resistant, 10 oz/sq yd, duck fabric, preferably cotton or predominantly cotton content for tents. One of the most important specifications and perhaps the most difficult to attain is the FR-finished fabric's tear strength of at least 6 lbs. Although by selecting a strong, long staple, combed cotton, it is possible to meet the required tear strength in the greige fabric, it is extremely difficult to retain the same strength level in the FR-finished fabric. By applying ARS core-spinning technology developed at SRRC and using only 10% (by weight of the yarn/fabric) gel-spun polyethylene (PE) staple fiber (only in the yarn core), we have been able to produce an almost 100%-cotton-surface fabric that meets the required military specification of tear strength in the filling direction and considerably exceeds it in the warp direction. This paper briefly describes various processes involved in converting fibers into a FR-finished fabric and properties of the yarns and fabrics produced.