The Ultimate Guide to Workwear for the Chemical Industry

Introduction: Beyond Basic Protection

The Hierarchy of Chemical Protection

• Level A: Vapor-protective suits for highest respiratory and skin protection needs (SCBA included).
• Level B: Liquid-splash protective suits for high protection against liquids but not vapors.
• Level C: Splash suits with lower-level respiratory protection (air-purifying respirators).
• Level D: Basic coveralls with no respiratory protection (for areas with no known hazards).

Most chemical manufacturing and handling tasks require Level B or C protection.

The Head-to-Toe Chemical Protection System

1. Primary Protective Garments

• Disposable Coveralls (Limited Use):
  • Best for: Short-term tasks, low-exposure risk, or contamination control (e.g., painting, dust, light splashes).
  • Materials:
    • Tyvek® (Polyethylene): Excellent barrier against fine particulates and dry chemicals. Not suitable for liquids or hazardous chemicals.
    • Microporous Film (e.g., Tychem® SL): Good protection against a range of liquids, aerosols, and particles. Lighter duty.
  • Key Features: Elastic cuffs, sealed seams, and zipper flaps enhance protection.
• Reusable Coveralls & Suits (Chemical-Specific):
  • Best for: Regular handling of hazardous liquids, acids, and solvents.
  • Materials (Selection is Critical):
    • PVC (Polyvinyl Chloride): Excellent resistance to acids, alkalis, and salts. Stiff in cold weather.
    • Neoprene: Superior resistance to oils, solvents, acids, and alkalis. Good physical durability.
    • Butyl Rubber: The gold standard for resistance to highly corrosive chemicals (e.g., ketones, esters) and gases.
    • Viton®/Fluoroelastomer: Exceptional resistance to chlorinated and aromatic hydrocarbons. Used for specialized, extreme hazards.
    • Nitrile Rubber: Excellent abrasion and puncture resistance, good for a range of chemicals.
  • Key Features: Fully sealed seams, gas-tight zippers, attached socks, and wide vision panels for hoods.

2. Gloves: Your First Line of Defense

• Material Guide:
  • Nitrile: Excellent general-purpose choice for oils, fats, solvents, and acids. Good puncture and abrasion resistance.
  • Neoprene: Good for acids, alkalis, alcohols, and solvents.
  • Butyl Rubber: Best for ketones (e.g., acetone) and esters. Also provides good gas permeability resistance.
  • PVC: Excellent for acids and alkalis but poor against many organic solvents.
  • Viton®: Specialized gloves for highly aggressive chemicals like chlorinated solvents.
• Features: Look for extended sleeves (gauntlets) to protect the wrist area, textured grips for dexterity, and appropriate thickness for your task.
• 

3. Safety Footwear

• Materials: PVC or Neoprene boots are common. For integrated protection, chemical-resistant rubber boots with steel toes are essential.
• Design: Knee-high or higher boots are often necessary to prevent splashes from entering. They should be worn over the suit's legs to create a sealed barrier.
• Standard: Must be ASTM F2413-18 rated for safety toe and puncture-resistant soles. EH (Electrical Hazard) rating may also be required.

4. Eye and Face Protection

• Chemical Splash Goggles: Primary choice. Must have indirect ventilation to prevent chemical entry. Must be ANSI Z87.1+ rated.
• Face Shields: Worn over goggles, not instead of them. Provides additional protection for the entire face from splashes.

5. Respiratory Protection

• Air-Purifying Respirators (APR): With appropriate chemical cartridges for known vapors/gases where oxygen levels are sufficient.
• Supplied Air Respirators (SAR): For higher concentration exposures or oxygen-deficient atmospheres.
• Self-Contained Breathing Apparatus (SCBA): For entry into IDLH (Immediately Dangerous to Life or Health) atmospheres or unknown concentrations.

Key Principles for Selection: The "Must-Check" List

1. Chemical Compatibility: This is the #1 rule. Always consult the Safety Data Sheet (SDS) for the chemicals you are handling. Use a chemical compatibility chart to match the garment material to the specific hazard.
   • Example: A Nitrile suit will degrade rapidly when exposed to acetone or strong oxidizers, while Butyl rubber would be effective.
2. Seam Construction: Seams are the weakest point.
   • Serged/Overlocked Seams: Basic stitching. Not liquid-tight.
   • Bound Seams: Fabric is wrapped with tape. Better, but not fully sealed.
   • Sealed Seams: The gold standard. A tape is thermally welded over the seam, creating a continuous barrier. Essential for liquid and vapor protection.
3. Dexterity vs. Protection: Thicker materials offer more protection but reduce touch sensitivity and mobility. Find the right balance for the task.
4. Duration of Exposure: How long could the worker be exposed in a splash scenario? This determines the required material strength and thickness.

Donning and Doffing: A Critical Safety Procedure

• Train Thoroughly: Establish a step-by-step procedure.
• Use a Buddy System: Have a second person observe to prevent cross-contamination.
• Decontaminate First: If exposed, decontaminate (e.g., use a safety shower) before doffing gear.
• Designated Area: Remove PPE in a designated, clean area to contain any contaminants.

Care and Maintenance of Reusable Garments

• Inspection: Check for signs of degradation, thinning, swelling, cracks, or holes before and after each use.
• Decontamination: Clean thoroughly according to the manufacturer's instructions using compatible cleaning agents.
• Retirement: Err on the side of caution. Retire any garment that shows the slightest sign of damage or permeation. Their protective lifespan is limited.

Conclusion

1. Identify the chemical hazards using the SDS.
2. Select the compatible material using a chemical resistance guide.
3. Choose the right garment design (seams, style, coverage) for the task.
4. Integrate all PPE (gloves, boots, goggles, respirator) to create a complete barrier.
5. Train extensively on proper use, limitations, and emergency procedures (like doffing).