This study investigates physicochemical impact of ultrasonic irradiations on surface topography of woven fabrics. In a simultaneous in-situ sonochemical method, the synthesis and coating of zinc oxide nanoparticles (ZnO NPs) on woven textiles were successfully achieved. Different instruments i.e. Alambeta, moisture management tester, air permeability tester and permetester were utilised during experimentation for thermal evaluation, moisture transportation and air permeation. The results regarding thermophysiological comfort of ZnO coated fabrics were evaluated on the basis of thickness and ZnO NPs coated amount on fabrics. In addition, the achieved results depict the impact of sonication (pressure gradient) on surface roughness of cotton and polyester. The coating of ZnO NPs on fabrics, crystal phase identification, surface topography and fluctuations in surface roughness were estimated by inductively coupled plasma atomic emission spectroscopy (ICP-AES), X-ray Diffractometry (XRD), ultrahigh-resolution scanning electron microscopy (UHR-SEM) and energy dispersive X-ray (EDX). Moreover, thermophysiological properties i.e. thermal conductivity, absolute evaporative resistance, thermal absorptivity, air permeability, overall moisture management capacity and relative water vapour permeability of untreated and ZnO treated samples were evaluated by standard test methods.