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    • Kappler · Hazmat suit comparison

    Kappler Zytron 500 vs DuraChem 500 vs Frontline 500

    Three Kappler 500 lines, three jobs: Zytron 500 offers the most styles (17), DuraChem 500 is the tactical non-encapsulating CBRN suit, and Frontline 500 adds chemical flash-fire protection for escape only.

    • Zytron 500Coveralls, splash and vapor total encapsulating suits for Level A and Level B applications, with greater than 8-hour holdout against every chemical in the ASTM F1001 test battery.
    • DuraChem 500A vapor-tight, non-encapsulating coverall with a tactical fit for general hazmat, military, police and terrorism response. Redesigned to be tactical, tough and PFAS free.
    • Frontline 500A gas-tight vapor suit with three-way protection: chemical, flash-fire and radiant heat. Flash-fire protection is for escape only, not for firefighting.
    Request a quote
    Compare side by side
    Kappler Zytron 500 vapor total encapsulating suit in hi-vis orange Zytron 500Total encapsulating & coverallsFull page Kappler DuraChem 500 non-encapsulating rear-entry suit in Khaki, worn with SCBA DuraChem 500Non-encapsulating CBRNFull page Kappler Frontline 500 silver vapor total encapsulating suit Frontline 500Chemical/FR vapor suitFull page
    At a glance

    Side by side

    The garment type, certified styles, chemical results and construction of each line. Certification always belongs to a specific style code, so check the suffix before you order.

    Kappler line Zytron 500Full page DuraChem 500Full page Frontline 500Full page
    The line
    Kappler positioningTop level protection for demanding hazmat response.Redesigned to be tactical, tough and PFAS free.NFPA 1990 (1991) apparel for chemical flash-fire protection.Flash-fire protection is for escape only.
    Garment typesCoveralls, splash and vapor total encapsulating suits, training suits and an overhoodVapor-tight, non-encapsulating coverall; also a non-certified coverall and training suitsVapor total encapsulating suit, expanded back
    Styles1772
    EntryFront, rear or front diagonal, by styleFront or rearFront or rear
    ColorsHi-vis orange and charcoal grayKhaki and NavySilver
    Typical applicationsHazmat response, chemical handling, refueling operations, petrochemical operations, hazardous material clean-up and remediation, CWA incineration, remediation and disposal.Acid handling, tank cleaning, petrochemical operations, agrichemical mixing/applicationsHazmat response and chemical handling situations with potential for chemical flash-fire.Flash-fire protection is for escape only.
    Certification (by style)
    NFPA certified styles Z5H577-92NFPA 1990 (1992) Certified Splash Protective Total Encapsulating SuitZ5H582-94C2RPBC · Z5H583-94C2RPBCNFPA 1990 (1994) Class 2 Certified Vapor Total Encapsulating Suit D5H457-94 · D5H457-94BC · D5H458-94 · D5H458-94BCNFPA 1990 (1994) Class 1 & 2 Certified Hazmat/CBRN Ensemble F5H582-91 · F5H583-91NFPA 1990 (1991) Certified Vapor Total Encapsulating Suit, including the optional Flash Fire and Liquified Gas requirements. Flash-fire protection is for escape only.
    Not NFPA certifiedAll other Zytron 500 styles, including Z5H582 and Z5H583 without the suffixD5H457 6E coverall and the D5S457 / D5S458 training suitsNone: both styles are certified
    Berry CompliantZ5H582-94C2RPBC and Z5H583-94C2RPBCThe -94BC styles—
    Protection
    Chemical test batteryASTM F1001 Chemical Test Battery: >480 minutes for every chemicalProven holdout against Chemical Warfare Agents (CWA).DuraChem 500 Chemical Test Battery: >60 minutes for every chemical at Class 1Class 1 challenge levels are 20 g/m2 for liquids and 10,000 ppm for gases and vapors.ASTM F1001 Chemical Test Battery: >480 minutes, except Dichloromethane 253Holdout for the ASTM F1001 battery and many additional chemicals.
    Mustard (HD), Sarin (GB), VX>480 minutes>480 minutes>480 minutes
    Viral penetrationASTM F1671: >60Blood/Viral, ASTM-F1671: Pass—
    Heat & flame—Designed for protection of personnel against short duration thermal exposures.Do not use for firefighting applications.TPP 32 (ISO 17492); meets ASTM F1358 flame resistance; 0% body burn after a six-second ASTM F1930 manikin test.For chemical flash-fire protection FOR ESCAPE ONLY in the event of a chemical flash fire. Do not use for firefighting applications.
    PFASZytron 500 fabric does not contain PFAS Chemistry. PFAS found in FEP lens at this time.PFAS free. DuraChem 500 fabric does not contain PFAS Chemistry.Frontline 500 fabric does not contain PFAS Chemistry. PFAS found in FEP lens at this time.
    Construction
    Face & visorAntiFog Expanded-View Visor System is standard on gas-tight stylesAdditional FEP Overlay on the Hazmat Model stylesAttached Hood with Sure-Fit® Respirator Face Piece SealFits securely around the respirator and eliminates the need for tapingExpanded View AntiFog Visor System with Additional FEP Overlay
    ClosureAquaSeal® Gas-Tight Zipper on vapor suits; zipper on coveralls and splash suitsAquaSeal® Gas-Tight Zipper on the certified styles; Double Storm Flaps with FR Hook & Loop ClosureAquaSeal® Gas-Tight Zipper; Double Storm Flaps with FR Hook & Loop Closure
    GlovesBy style: Attached Field Replaceable Butyl Gloves, Attached Field Replaceable 2N1® Glove System (Hazmat Model), Field Replaceable 2N1® Glove System with Removable Overglove (certified Class 2), Permanently Attached Neoprene Gloves (Z5H577-92)Permanently Attached 22 mil Bromobutyl Gloves with Removable Touchscreen Overgloves (certified styles)Field Replaceable 2N1® Glove System and Removable Overgloves
    Exhaust2 Exhaust Valves on vapor suits and Z5H577-92; 1 Exhaust Port on splash and training suits—2 Exhaust Valves
    SeamsHeat Sealed / Taped (training suits: Serged)Heat Sealed / Taped (training suits: Serged)Heat Sealed / Taped on Inner and Outer Seams
    FeetAttached Sock Booties with Splash Guards on every style except the Z5H428 coverall and the overhoodAttached Sock Booties with Splash Guards, Hook & Loop Fasteners at AnklesAttached Sock Booties with Splash Guards
    Use & sizing
    UseMultiple use, single exposureMulti-use, single exposure; launderable up to five washes if not contaminatedMultiple uses, single exposure
    Storage life10 years from date of manufacture10 years from date of manufacture10 years from date of manufacture
    SizesSM/MD, LG/XL, 2X/3X, 4XLZ5H750 overhood: one sizeSM/MD, LG/XL, 2X/3X, 4XLSM/MD, LG/XL, 2X/3X, 4XL

    — : not stated for that line. Chemical results are in minutes and come from tests on fabric samples by independent laboratories, not finished garments.

    Which one fits

    Match the suit to the job

    Each line answers a different call. Start with the hazard and how your team works, then open the full page to pick a style and size.

    Responder in an orange Kappler Zytron 500 gas-tight suit with SCBA in the field
    Total encapsulating & coveralls

    Zytron 500

    For hazmat teams that want one fabric across coveralls, splash suits and vapor suits for Level A and Level B applications.

    1. Holdout. Greater than 8-hour holdout against every chemical in the ASTM F1001 test battery, with proven holdout against Chemical Warfare Agents (CWA).
    2. Range. 17 styles, from hooded coveralls to flat back and expanded back vapor suits, in hi-vis orange and charcoal gray.
    3. Certified styles. Z5H577-92 to NFPA 1990 (1992) as a splash suit; Z5H582-94C2RPBC and Z5H583-94C2RPBC to NFPA 1990 (1994) Class 2 as vapor suits, Berry Compliant.

    Coveralls · splash suits · vapor suits · training suits · overhood

    See full Zytron 500 page
    Responder in a Khaki Kappler DuraChem 500 suit with SCBA working at leaking drums
    Non-encapsulating CBRN/HazMat

    DuraChem 500

    For general hazmat, military, police and terrorism response teams that want a vapor-tight, non-encapsulating coverall with a tactical fit.

    1. Certified styles. D5H457-94, D5H458-94 and the Berry Compliant -94BC styles are dual-certified for both CBRN and Hazmat response to NFPA 1990 (1994) Class 1 and Class 2.
    2. Tactical fit. Sure-Fit® face piece seal around the respirator, exterior helmet wearability and glove dexterity with touch screen capability.
    3. PFAS free. DuraChem 500 fabric does not contain PFAS Chemistry. Made in USA, and launderable up to five washes if not contaminated.

    Certified suits · non-certified coverall · training suits

    See full DuraChem 500 page
    Responder in a silver Kappler Frontline 500 suit working at a valve in a vapor cloud
    Chemical/FR protection

    Frontline 500

    For hazmat response and chemical handling situations with potential for chemical flash-fire. Flash-fire protection is for escape only.

    1. Three-way protection. Chemical, flash-fire and radiant heat: TPP 32 (ISO 17492) and 0% body burn after a six-second ASTM F1930 manikin test. For escape only in the event of a chemical flash fire; do not use for firefighting applications.
    2. Certified styles. F5H582-91 (front entry) and F5H583-91 (rear entry) are certified to NFPA 1990 (1991), including the optional Flash Fire and Liquified Gas requirements. Flash-fire protection is for escape only.
    3. Gas-tight build. AquaSeal® gas-tight zipper, Expanded View AntiFog Visor System with Additional FEP Overlay, and the Field Replaceable 2N1® Glove System and Removable Overgloves.

    Vapor total encapsulating suits · front or rear entry

    See full Frontline 500 page
    NFPA 1990

    One standard, four parts

    NFPA 1991, 1992 and 1994 are now consolidated under NFPA 1990. Each certified Kappler 500 style is certified to one or two of its parts. Here is what each part asks of the ensemble, and which styles carry it.

    NFPA 1990 (1991)

    Vapor & liquid

    Hazardous Materials and CBRN Operations Vapor and Liquid

    Chemical resistance
    Permeation resistance 1 hr vs 21 industrial chemicals, 4 toxic industrial chemicals and agents mustard and soman
    Challenge level
    Liquids 100 g/m2 Concentration · Vapors 100%
    System tests
    ASTM F1052 Pressure · MIST Inward Leakage PPDF > 488 · Shower > 60 min
    Certified styles
    NFPA 1990 (1992)

    Liquid splash

    Hazardous Materials and CBRN Operations Liquid Splash

    Chemical resistance
    Penetration resistance 1 hr vs 10 industrial chemicals
    Breakthrough
    ASTM F903 Visual liquid
    System tests
    ASTM F1359 Shower > 20 min
    Certified style
    NFPA 1990 (1994) Class 1

    Vapor & liquid

    Hazardous Materials and CBRN Operations Vapor and Liquid

    Chemical resistance
    Permeation resistance 1 hr vs 10 toxic industrial chemicals and agents mustard and soman
    Challenge level
    Liquids 20 g/m2 concentration · Vapors 10,000 ppm Closed Top Cell
    System tests
    MIST PPDF > 441 · ASTM F1359 Shower > 20 min
    Certified styles
    NFPA 1990 (1994) Class 2

    Vapor & liquid

    Hazardous Materials and CBRN Operations Vapor and Liquid

    Chemical resistance
    Permeation resistance 1 hr vs 5 toxic industrial chemicals and agents mustard and soman
    Challenge level
    Liquids 10 g/m2 concentration · Vapors 350 ppm Closed Top Cell
    System tests
    MIST PPDF > 328 · ASTM F1359 Shower > 20 min
    Certified styles

    Zytron 500. Z5H582 and Z5H583 without the -94C2RPBC suffix are Hazmat Model vapor suits and are not NFPA certified.

    DuraChem 500. The D5H457 6E coverall and the training suits are not NFPA certified. For Class 1 applications, don the provided outer glove.

    Frontline 500. Certification includes base plus Optional Flash Fire and Liquified Gas requirements. Flash-fire protection is for escape only.

    Chemical test data

    Selected chemicals, side by side

    The same chemicals from each fabric's chemical test data, with results in minutes. Most results are greater than 480 minutes; the differences are highlighted.

    Chemical NameCASResult
    Zytron 500DuraChem 500Frontline 500
    Chemical warfare agents
    Sarin (GB)107-44-8>480>480>480
    Nerve agent (VX)50782-69-9>480>480>480
    Mustard (HD)505-60-2>480>480>480
    Soman 20 g/m296-64-0>60>60>60
    Toxic industrial gases
    Chlorine Gas7782-50-5>480>480>480
    Hydrogen Chloride gas7647-01-0>480>480>480
    Hydrogen Fluoride Gas 99%7664-39-3>480180>480
    Hydrogen Sulfide 100% Vapor7783-06-4>480—>480
    Ethylene Oxide75-21-8>480>480>480
    1,3-Butadiene106-99-0>480>480>480
    Acids & bases
    Sulfuric Acid, 98%7664-93-9>480>480>480
    Nitric Acid, 70%7697-37-2>480>480>480
    Nitric Acid 99%7697-37-2—76>480
    Hydrofluoric Acid 48%7664-39-3>480>480>480
    Hydrochloric Acid, 37%7647-01-0>480>480>480
    Sodium Hydroxide, 50%1310-73-2>480>480>480
    Solvents & fuels
    Acetone67-64-1>480>480>480
    Benzene71-43-2>480>480>480
    Toluene108-88-3>480>480>480
    Methyl Ethyl Ketone78-93-3>480>480>480
    Dichloromethane75-09-2>480—253
    Dimethylhydrazine N,N-57-14-7>48035—
    Gasoline8006-61-9>480>480>480
    JP 8 Jet Fuelmixture>480>480>480

    — : not in that fabric's chemical test data. Sources for all chemical test data are independent laboratories. All tests were performed under laboratory conditions and not under actual use conditions. Tests were performed on material samples, not actual garments. All chemicals tested at 95% and 75° F unless otherwise specified. All chemical test data shown is “permeation” based on ASTM F739, unless noted as “LIQUID PENETRATION” based on ASTM F903/F1671. Results displayed are in minutes. Select chemicals based on permeation when liquid and vapor protection is required. Select penetration when only liquid protection is required.

    Test batteries

    Each line publishes a short test battery alongside its full chemical list. Zytron 500 and Frontline 500 report the ASTM F1001 battery; DuraChem 500 reports its battery at the NFPA 1990 (1994) Class 1 and Class 2 challenge levels.

    Zytron 500>480minutes for every chemical in the ASTM F1001 Chemical Test Battery
    DuraChem 500>60minutes for every chemical in the DuraChem 500 Chemical Test Battery at Class 1, plus Soman and Distilled Mustard
    Frontline 500>480minutes in the ASTM F1001 Chemical Test Battery, except Dichloromethane at 253

    Every suit's SMART™ label carries a QR code: a quick scan provides complete chemical data plus extensive suit details. Ask us about a specific chemical at sales@farrwest.com or 210.566.1857.

    In detail

    Respirator, fit & care

    What each line needs alongside it, and how to inspect, test and store it.

    Respirator & fitZytron 500Full pageDuraChem 500Full pageFrontline 500Full page
    Respiratory protectionSeparate full-face respiratory protection such as a self-contained breathing apparatus (SCBA) or an external breathing air supply (airline system with garment pass-through) with escape bottleThe Sure-Fit® face piece seal fits securely around the respiratorSeparate NIOSH approved full-face respiratory protection such as a self-contained breathing apparatus (SCBA) or an external breathing air supply (airline system with garment pass-through) with escape bottle
    Certified ensemblesMust be used with NIOSH CBRN approved SCBAMust be used with NIOSH CBRN approved SCBAMust use NIOSH CBRN approved SCBA
    Respirators testedScott AV3000 face-piece with SCBA; may be used with any SCBA certified as compliant with NFPA 1981Certified Class 2 ensembleScott Safety AV-3000, Scott Safety AV-3000 HT (Sure Seal), Draeger DHR 7000, Draeger FPS 7000, MSA Ultra Elite, MSA G1Scott AV 3000 HT Sure Seal
    Supplied airRequires the appropriate NIOSH approved garment pass-through—Requires the appropriate NIOSH approved garment pass-through
    HelmetWill accommodate Type 1 Class G helmets of ANSI Z89.1Certified Class 2 ensembleDesigned for exterior helmet wearability for tactical response; will accommodate a Type 1 Class G helmet—
    Outer bootsSock booties are designed to be worn inside outer bootsSeparate outer safety boots must be wornSeparate outer safety boots must be worn
    UnderneathConsider inherently flame resistant, woven clothing, with full-length sleeves and trousersConsider inherently flame resistant, woven clothing, with long sleeves and pantsConsider inherently flame resistant, woven clothing, with long sleeves and pants
    Inspection & careZytron 500Full pageDuraChem 500Full pageFrontline 500Full page
    Pressure testGas-tight suits: procedure mirrors ASTM F1052. Inflate to 5.0 inches of water column, reduce to 4.0; passed if the pressure has not dropped below 3.2 after four (4) minutesNot required for non-encapsulating garments per NFPA 1891; Kappler's AKM007 adaptor with the AKMOC pressure test kit verifies vapor-tight integrity using ASTM F1052Procedure mirrors ASTM F1052. Inflate to 5.0 inches of water column, reduce to 4.0; passed if the pressure has not dropped below 3.2 after four (4) minutes
    InspectionNever wear garments that have not been fully inspected and pressure tested prior to useFull visual inspection upon receipt, prior to donning, after wear and before reuse, and annuallyFull visual inspection upon receipt, prior to donning, after wear and before reuse, and annually
    Laundering—Up to five washes if not contaminated: front-loading or other non-agitator machine, cold water (less than 105 degrees F), air-dry only—
    DecontaminationWater and mild household dishwashing liquid onlyWater and mild household dishwashing liquid onlyWater and mild household dishwashing liquid only
    Storage lifePredicted storage life of 10 years from the date of manufacture when stored properly, based on accelerated aging studiesPredicted storage life of 10 years from the date of manufacture when stored properly, based on accelerated aging studiesPredicted storage life of 10 years from the date of manufacture when stored properly, based on accelerated aging studies
    StorageAway from direct sunlight or UV exposure; cool (between 40º and 90º F), dry, well-ventilated; closures in the open positionAway from direct sunlight or UV exposure; cool (between 40º and 90º F), dry, well-ventilated; closures in the open positionAway from direct sunlight or UV exposure; cool (between 40º and 90º F), dry, well-ventilated; closures in the open position
    Retired garmentsIf not contaminated, may be labeled and used “For Training Use Only.”If not contaminated, may be labeled and used “For Training Use Only.”If not contaminated, may be labeled and used “For Training Use Only.”
    Resources

    Full pages & downloads

    Full page

    Zytron 500

    All 17 styles, chemical test data, NFPA certified styles and line specifications.

    Open page     Full page

    DuraChem 500

    All 7 styles, tactical design, NFPA Class 1 and Class 2 data, fit and care.

    Open page     Full page

    Frontline 500

    Both certified styles, heat, flame and thermal data, chemical test data and use.

    Open page     Standards

    NFPA standards guide

    A concise reference to the protective clothing standards consolidated under NFPA 1990. PDF · Kappler

    Download     PFAS

    PFAS statement

    PFAS and PPE: what it means to the end user of Kappler protective garments. PDF · Kappler

    Download
    FAQ

    Comparing the 500s

    What is the main difference between Zytron 500, DuraChem 500 and Frontline 500?
    The garment and the hazard. Zytron 500 comes as coveralls, splash and vapor total encapsulating suits for Level A and Level B applications. DuraChem 500 is a vapor-tight, non-encapsulating coverall with a tactical fit for general hazmat, military, police and terrorism response. Frontline 500 is a gas-tight vapor total encapsulating suit with chemical, flash-fire and radiant heat protection; its flash-fire protection is for escape only, and it must not be used for firefighting applications.
    Which styles are NFPA certified?
    Certification belongs to the style. Zytron 500: Z5H577-92 to NFPA 1990 (1992), and Z5H582-94C2RPBC and Z5H583-94C2RPBC to NFPA 1990 (1994) Class 2. DuraChem 500: D5H457-94, D5H457-94BC, D5H458-94 and D5H458-94BC to NFPA 1990 (1994) Class 1 and Class 2. Frontline 500: F5H582-91 and F5H583-91 to NFPA 1990 (1991), including the optional Flash Fire and Liquified Gas requirements; flash-fire protection is for escape only. Other styles, such as Zytron 500 Z5H582 and Z5H583 without the suffix, the DuraChem 500 D5H457 6E coverall and the training suits, are not NFPA certified.
    Which one is PFAS free?
    DuraChem 500: Kappler describes it as redesigned to be tactical, tough and PFAS free, and DuraChem 500 fabric does not contain PFAS Chemistry. Zytron 500 fabric and Frontline 500 fabric do not contain PFAS Chemistry either, but PFAS are found in the FEP lens: the outer layer of the gas-tight visor system. Kappler states that this layer contains no PFOA or PFOS and does not have sustained contact with the wearer's skin. See the PFAS statement.
    Can any of these suits be used for firefighting?
    No. Unless otherwise indicated, no Kappler products are intended as fire protection or for use in firefighting applications, open flame or intense heat. Frontline garments are designed for chemical flash-fire protection for escape only in the event of a chemical flash fire. DuraChem 500 and Frontline 500 are designed for protection of personnel against short duration thermal exposures; do not use them for firefighting applications and minimize exposure to open flame or intense heat.
    Encapsulating or non-encapsulating: what changes?
    Vapor protective garments such as the Zytron 500 vapor suits and Frontline 500 totally enclose the wearer and isolate the wearer from exposure to outside gases and vapors. DuraChem 500 non-encapsulating coveralls are designed to be vapor tight: the attached hood's Sure-Fit® face piece seal fits securely around the respirator, and the suit is designed for exterior helmet wearability for tactical response.
    Can each suit be pressure tested?
    Yes. For the gas-tight Zytron 500 suits and Frontline 500, Kappler's procedure mirrors ASTM F1052: inflate to 5.0 inches of water column, reduce to 4.0, and after four (4) minutes the garment has passed if the pressure has not dropped below 3.2 inches water column. Non-encapsulating garments are not required to be pressure tested per NFPA 1891, but Kappler designed an adaptor (AKM007) for use with the pressure test kit (AKMOC) so the vapor-tight integrity of DuraChem 500 can be verified using ASTM F1052.
    Are they reusable?
    All three are multi-use, single exposure garments: contaminated garments should be discarded. DuraChem 500 is also launderable up to five washes if not contaminated. Retired garments that are not contaminated may be labeled and used "For Training Use Only."
    How long can I store them, and what sizes are available?
    Each line has a predicted storage life of 10 years from the date of manufacture when stored properly: away from direct sunlight or UV exposure, cool (between 40º and 90º F), dry and well ventilated, with the closures in the open position. All three lines are available in SM/MD, LG/XL, 2X/3X and 4XL; the Zytron 500 overhood is one size.
    How do the chemical test results compare?
    It depends on the chemical. Zytron 500 shows greater than 480 minutes for every chemical in the ASTM F1001 Chemical Test Battery; Frontline 500 shows greater than 480 minutes for all of them except Dichloromethane at 253. DuraChem 500 publishes its battery at the NFPA Class 1 and Class 2 challenge levels. Compare the selected chemicals above, scan the QR code on the suit's SMART™ label for complete chemical data, or ask us about a specific chemical.
    Next step

    Still choosing between the 500s?

    Tell us the hazards, how your team responds and the sizes you need, and we'll help you match Zytron 500, DuraChem 500 or Frontline 500 styles to the job.

    Request a quote
    Call 210.566.1857
    Or email sales@farrwest.com

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