Introduction 

Chemical exposure is not a distant threat; it’s a daily reality in industrial environments these days. Whether in laboratories, manufacturing plants, oil refineries, or agricultural operations, workers regularly handle corrosive, toxic, or reactive substances that can cause serious injuries to the skin, eyes, and respiratory system.  

One stark example occurred in 2022, when OSHA fined a manufacturing facility in Ohio $43,000 after a worker sustained severe sulfuric acid burns. The investigation revealed multiple safety lapses, such as failure to consult the Safety Data Sheet (SDS) for required PPE, inadequate provision of chemical-resistant gloves and coveralls, and lack of worker training on chemical exposure risks.  

CRC not only protects lives but also ensures regulatory compliance and prevents costly legal consequences.  

This comprehensive guide provides an overview of chemical-resistant clothing, including key features to look for, how to interpret SDS and OSHA standards, and training and compliance essentials

 

What Is Chemical-Resistant Clothing? 

Chemical-resistant clothing refers to personal protective equipment (PPE). This type of clothing is designed to shield workers from hazardous chemicals, liquids, vapors, and particles. It acts as a barrier, reducing or eliminating skin contact and preventing chemical burns, irritation, or systemic toxicity caused by absorption. 

Chemical Resistant Clothing includes: 

  • Coveralls 
  • Aprons 
  • Gloves 
  • Boots 
  • Sleeves 
  • Full-body suits 

The clothing is made from materials like PVC, neoprene, butyl rubber, and polyethylene, each offering different levels of protection based on chemical type and exposure duration. 

 

Why is Chemical-Resistant Clothing Important? 

 When a chemical spill, splash or leak occurs, then direct skin contact with chemicals can lead to: 

  • Severe burns and irritation. 
  • Long-term skin conditions like dermatitis. 
  • Systemic poisoning via dermal absorption. 
  • Carcinogenic exposure or reproductive hazards. 

In these situations, wearing appropriate chemical-resistant clothing can make the difference between life and death in workplaces where exposure to acids, solvents, pesticides, or toxic gases is part of the job. 

 

OSHA Requirements for Chemical Protective Clothing 

The Occupational Safety and Health Administration (OSHA) mandates that employers must provide PPE when hazards are present. Check out what OSHA says: 

According to the OSHA PPE Standard 29 CFR 1910.132 

Employers must: 

  • Select the appropriate PPE. 
  • Train workers on its use, limitations, and maintenance. 
  • Ensure PPE is properly fitted and maintained. 

 

According to the OSHA 29 CFR 1910.120 (Hazardous Waste Operations) 

This regulation is meant for choosing the PPE for chemical exposure in hazardous waste operations and emergency response scenarios. 

OSHA also has standards for certain chemicals, such as: 

  • Formaldehyde (29 CFR 1910.1048) 
  • Benzene (29 CFR 1910.1028) 
  • Ethylene oxide (29 CFR 1910.1047) 

In each case, chemical-resistant clothing must be used when skin exposure is a risk. 

 

How SDS (Safety Data Sheets) Help in Clothing Selection 

SDSs (Safety Data Sheets) contain essential information for choosing chemical-resistant clothing. As per OSHA’s Hazard Communication Standard (29 CFR 1910.1200), each SDS comprises 16 sections. 

Look for the following SDS sections when choosing PPE: 

  • Section 2: Hazard Identification

    This section helps to determine if the chemical is corrosive, flammable, or toxic. 

  • Section 8: Exposure Controls/Personal Protection

    This section lists recommended PPE, including gloves, suit materials, and face protection. 

  • Section 9: Physical and Chemical Properties

    This section is meant for understanding volatility and reactivity for better selection of fabric resistance. 

  • Section 11: Toxicological Information

    This section indicates the risks of dermal exposure or sensitization.

 

6 Key Features to Look for in Chemical-Resistant Clothing 

When safety officers or EHS managers are choosing chemical-resistant garments, they need to consider the following: 

i) Permeation Resistance

It is the rate at which chemicals can pass through the fabric. Safety managers need to refer to the rate at which a chemical can pass through the fabric on a molecular level.  Garments should have low permeation rates against the chemicals listed in the Safety Data Sheet (SDS) for any industry. 

 

ii) Penetration Protection 

EHS managers need to ensure the clothing prevents bulk movement of liquids or particles through closures, seams, or imperfections. They must inspect sealed or welded seams and secure closures to prevent chemical leaks. 

 

iii) Degradation Resistance

The material (fabric) should not degrade, stiffen, or weaken when exposed to specific chemicals over time.  EHS managers or PPE specialists need to verify compatibility with the chemicals in use to avoid garment failure during critical operations. 

 

iv) Suit Design

A well-designed suit always increases safety and functionality. Full-body coverage, chemical-resistant zippers, elastic cuffs, and storm flaps are essential to ensure maximum protection from exposure. 

 

v) Breathability and Comfort

Breathable, lightweight materials can reduce heat stress during long wear times. These types of suits improve worker compliance and performance, especially in hot or enclosed environments.] 

 

vi) Compliance Certification

EHS manager, procurement officer, or safety compliance team must check out that the suits meet the recognized safety standards like ASTM F739 (Permeation resistance), NFPA 1992/1994 (Hazardous liquid splash protection, EN ISO 6529 (Chemical permeation testing). By verifying these, they can ensure documented performance levels and support full OSHA compliance. 

 

How to Select the Right Clothing Based on Hazard Level 

Not all exposure gives equal impact. That’s why; OSHA recommends a risk-based approach: 

i) Low Risk Situation 

  • Diluted chemicals, splash exposure. 
  • Use: Aprons, gloves, safety goggles. 

 

ii) Moderate Risk Situation 

  • Prolonged exposure, frequent handling. 
  • Use: Coveralls, boots, full face shields. 

 

iii) High Risk Situation 

  • Toxic, corrosive, or high-pressure chemicals. 
  • Use: Full-body suits, SCBA (self-contained breathing apparatus), multi-layered protection. 

 

Training & Maintenance: What OSHA Requires 

Organizations handling hazardous substances need to arrange training on proper use, maintenance, and disposal of chemical-resistant clothing. Employees must learn and become aware through the training about:  

  • How to put on and take off PPE correctly. 
  • How to inspect for tears, wear, or permeation. 
  • Storage away from sunlight, moisture, and chemicals. 
  • Cleaning instructions based on manufacturer guidance. 
  • When to replace disposable or worn items. 

Employers and EHS supervisors must conduct the above-mentioned training and update them on the arrival of new PPEs. 

 

6 Common Industry Applications 

 Check out the following industries where chemical-resistant clothing is essential- 

  • Oil & Gas: For acidizing operations, chemical injections. 
  • Agriculture: Handling pesticides and herbicides. 
  • Laboratories: Dealing with reagents and volatile solvents. 
  • Chemical Manufacturing: Processing, mixing, or transferring hazardous substances. 
  • Pharmaceuticals: Cleanroom protection from chemical residues. 
  • Waste Management: Treating or cleaning up hazardous waste. 

 

Conclusions 

For any organization, choosing proper chemical-resistant clothing is essential. However, the organization must ensure that its employees have a comprehensive understanding of OSHA compliance, including the ability to read and interpret SDSs, recognize chemical exposure risks, and receive training on PPE quality maintenance.  

When lives are at risk, there’s no room for compromising with chemical-resistant clothing. Accurate selection of this type of clothing and usage are critical components to maintain workplace safety.