Redesigned to be tactical, tough and PFAS free
The redesigned DuraChem 500 CBRN suit combines maximum protection with an affordable price. Its NFPA-certified styles are a vapor-tight, non-encapsulating coverall with superior glove dexterity and a tactical fit for general hazmat, military, police and terrorism response. The family also includes a non-encapsulating coverall and two training suits, in front- or rear-entry styles.
Rear-entry style shown
Every DuraChem 500 style starts from the same hood, Sure-Fit® face piece seal, attached sock booties and ankle straps. What changes is certification, Berry compliance, the zipper and the entry side. Answer in order.
Training suits keep the attached hood with Sure-Fit® face piece seal, sock booties and ankle fasteners, with serged seams and a plain front- or rear-entry zipper. Retired garments that are not contaminated may also be labeled and used "For Training Use Only."
The certified styles are dual-certified for both CBRN and Hazmat response to NFPA 1990 (1994) Class 1 and Class 2, and carry the -94 suffix.
The BC suffix marks the Berry Compliant ensembles.
Both certified entries close with an AquaSeal® gas-tight zipper under double storm flaps. The rear-entry design enhances frontal splash protection.
Kappler product numbers spell out the fabric, seam, garment, color, size and NFPA detail. Example for style D5H457-94:
So D5H458-94BC is a DuraChem 500, heat sealed/taped, rear-entry coverall, certified to NFPA 1990 (1994) and Berry Compliant.
Every style is stocked in SM/MD, LG/XL, 2X/3X and 4XL. Pick a style to choose your size and see pricing.
Shared construction: Non Encapsulating Coverall with Attached Hood with Sure-Fit® Respirator Face Piece Seal, Double Storm Flaps with FR Hook & Loop Closure, Permanently Attached 22 mil Bromobutyl Gloves with Removable Touchscreen Overgloves, Attached Sock Booties with Splash Guards, Hook & Loop Fasteners at Ankles.
DuraChem® 500 NFPA 1990 (1994) Class 1 & 2 Certified Hazmat/CBRN Ensemble.
DuraChem® 500 NFPA 1990 (1994) Class 1 & 2 Certified Hazmat/CBRN Berry Compliant Ensemble.
DuraChem® 500 NFPA 1990 (1994) Class 1 & 2 Certified Hazmat/CBRN Ensemble.
DuraChem® 500 NFPA 1990 (1994) Class 1 & 2 Certified Hazmat/CBRN Berry Compliant Ensemble.
Kappler's DuraChem® 500 Non-Encapsulating Coverall: front entry, heat sealed / taped seams, Khaki.
DuraChem® 500 Non-Encapsulating Coverall.
Shared construction: Coverall with Attached Hood with Sure-Fit® Respirator Face Piece Seal, Single Storm Flap with Hook & Loop Closure, Permanently Attached Gloves, Attached Sock Booties with Splash Guards, Hook & Loop Fasteners at Ankles.
DuraChem® 500 Training Suit.
DuraChem® 500 Training Suit.
Kappler designed an adaptor (AKM007) to be used with the pressure test kit (AKMOC) so the vapor-tight integrity of the garment can be verified using ASTM F1052.
Kappler Digital Pressure Test Kit Sure-Fit Face Seal Adapter for pressure testing DuraChem® 500.
AKMOC · Test kitKappler Digital Pressure Test Kit, used with the AKM007 adaptor to verify vapor-tight integrity.
99402 YW · For markingCase of 24 rolls. Ensembles may be marked with Kappler ChemTape®; adhesive tape may not be used as a means to create interfaces between ensemble elements.
Tactical, tough and PFAS-free.
DuraChem 500 fabric does not contain PFAS chemistry.Kappler
Kappler's PFAS statement: "all Provent® and Zytron® fabrics, as well as Durachem 500 products, do not contain PFAS." Read the PFAS statement (PDF).
DuraChem 500 is made in the USA, and the -94BC styles are Berry Compliant ensembles.
Multi-use, single exposure and launderable up to five washes if not contaminated.
A non-encapsulating coverall with a Sure-Fit® face piece seal, exterior helmet wearability and superior glove dexterity.
Certified styles have Permanently Attached 22 mil Bromobutyl Gloves with Removable Touchscreen Overgloves. Outer gloves must be worn for Class 1 and 2 compliance, and a pair is included with every certified suit.
On the certified styles, a 40-48" long gas-tight polyurethane coated zipper with heavy duty molded nylon teeth and stainless steel slider components, protected by a flap of garment material and fastened by a hook/loop system.
On the certified styles: single needle lock stitch seams with nylon thread, with chemical barrier film tapes heat-sealed over the inside seam.
Kappler's SMART™ label makes sizing easy to see, and a quick QR code scan provides complete chemical data plus extensive suit details.
DuraChem 500 offers pressure testing capability for gas-tight assurance. Non-encapsulating garments are not required to be pressure tested, but Kappler designed an adaptor (Kappler part AKM007) to be used with the pressure test kit (Kappler part AKMOC) so the vapor-tight integrity of the garment can be verified using ASTM F1052.
Certified to NFPA 1990 (1994) Class 1 and Class 2, DuraChem 500 offers CBRN/Hazmat protection in a tactical style garment. In addition to Chem-Bio requirements, the NFPA standard includes general Hazmat response, expanding its range of applications.
Certified styles: D5H457-94, D5H457-94BC, D5H458-94 and D5H458-94BC. For Class 1 applications, don the provided outer glove.
Class 1 chemical challenge levels are 20 g/m2 for liquids and 10,000 ppm for gases and vapors. Class 2 chemical challenge levels are 10 g/m2 for liquids and 350 ppm for gases and vapors.
| Chemical | Class 1 Minutes | Class 2 Minutes | Breakthrough Criteria |
|---|---|---|---|
| Acrolein | >60 | >60 | >6.0 ug/cm2 |
| Acrylonitrile | >60 | >60 | >6.0 ug/cm2 |
| Ammonia | >60 | >60 | >6.0 ug/cm2 |
| Chlorine | >60 | >60 | >6.0 ug/cm2 |
| Diethylamine | >60 | NA | >6.0 ug/cm2 |
| Dimethyl Sulfate | >60 | >60 | >6.0 ug/cm2 |
| Ethyl Acetate | >60 | NA | >6.0 ug/cm2 |
| Sulfuric Acid | >60 | NA | >6.0 ug/cm2 |
| Tetrachloroethylene | >60 | NA | >6.0 ug/cm2 |
| Toluene | >60 | NA | >6.0 ug/cm2 |
| Chemical Agent | Class 1 Minutes | Class 2 Minutes | Breakthrough Criteria |
|---|---|---|---|
| Soman | >60 | >60 | 1.25 ug/cm2 |
| Distilled Mustard | >60 | >60 | 4.0 ug/cm2 |
| Hazard | Method | Result |
|---|---|---|
| Blood/Viral | ASTM-F1671 | Pass |
These tests were performed in accordance with ASTM or other appropriate testing methods by independent laboratories. This data is derived from tests performed on material samples only, not finished garments.
Kappler's chemical test data for DuraChem 500 fabric list 173 chemicals tested. A selection, grouped by type, with results in minutes:
| Chemical Name | CAS | Result |
|---|---|---|
| Sarin (GB) | 107-44-8 | >480 |
| Nerve agent (VX) | 50782-69-9 | >480 |
| Mustard (HD) | 505-60-2 | >480 |
| Lewisite (L) | 541-25-3 | 240 |
| Distilled Mustard 20 g/m2 | 505-60-2 | >60 |
| Soman 20 g/m2 | 96-64-0 | >60 |
| Chemical Name | CAS | Result |
|---|---|---|
| Ammonia, gas, 10,000 ppm | 7664-44-7 | >60 |
| Chlorine, 10,000 ppm | 7782-50-5 | >60 |
| Chlorine Gas | 7782-50-5 | >480 |
| Hydrogen Chloride gas | 7647-01-0 | >480 |
| Hydrogen Fluoride Gas 99% | 7664-39-3 | 180 |
| Ethylene Oxide | 75-21-8 | >480 |
| 1,3-Butadiene | 106-99-0 | >480 |
| Vinyl Chloride | 75-01-04 | >480 |
| Acrolein, 10,000 ppm | 107-02-8 | >60 |
| Chemical Name | CAS | Result |
|---|---|---|
| Sulfuric Acid, 98% | 7664-93-9 | >480 |
| Sulfuric Acid, 98% LIQUID PENETRATION | 7664-93-9 | >60 |
| Hydrochloric Acid, 37% | 7647-01-0 | >480 |
| Hydrofluoric Acid 48% | 7664-39-3 | >480 |
| Nitric Acid, 70% | 7697-37-2 | >480 |
| Nitric Acid 99% | 7697-37-2 | 76 |
| Acetic Acid, 99% | 64-19-7 | >480 |
| Phosphoric Acid, 85% | 7664-38-2 | >480 |
| Oleum (27% SO3) | 8014-95-7 | >480 |
| Sodium Hydroxide, 50% | 1310-73-2 | >480 |
| Potassium Hydroxide, 45% | 1310-58-3 | >480 |
| Chemical Name | CAS | Result |
|---|---|---|
| Acetone | 67-64-1 | >480 |
| Benzene | 71-43-2 | >480 |
| Toluene | 108-88-3 | >480 |
| Hexane | 110-54-3 | >480 |
| Methyl Ethyl Ketone | 78-93-3 | >480 |
| Tetrahydrofuran | 109-99-9 | >480 |
| Dimethylformamide | 68-12-2 | >480 |
| Carbon Disulfide | 75-15-0 | >480 |
| Gasoline | 8006-61-9 | >480 |
| JP 8 Jet Fuel | mixture | >480 |
| Chemical Name | CAS | Result |
|---|---|---|
| Dimethylhydrazine N,N- | 57-14-7 | 35 |
| Dimethyl Sulfate | 77-78-1 | >480 |
| Toluene-2,4-diisocyanate | 584-84-9 | >480 |
| Hexamethylene-1,6-diisocyanate | 822-06-0 | >480 |
| Epichlorohydrin | 106-89-8 | >480 |
| Aniline | 62-53-3 | >480 |
| Viral penetration | ASTM F1671 | >60 |
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.
Typically worn over other clothing, Kappler's garments are designed so that "combination sizes" comfortably fit the vast majority of users.
Combo-Sizing Protective Clothing Chart. DuraChem 500 styles are stocked in SM/MD, LG/XL, 2X/3X and 4XL.
| Glove Size | Hand Circumference (in) | Hand Length (in) | Garment Size Option |
|---|---|---|---|
| Small | 7 | 6-3/4 | SM/MD |
| Medium | 8 | 7-3/16 | SM/MD |
| Large | 9 | 7-9/16 | LG/XL |
| X-Large | 10 | 8-1/16 | LG/XL |
| 2X-Large | 11 | 8-7/16 | 2X/3X, 4X |
Durachem 500 garments can be washed up to 5 times without compromising chemical barrier, if not contaminated.
Front-loading or other non-agitator machine, cold water (less than 105 degrees F), low sudsing detergent. Air-dry only.
A predicted storage life of 10 years from the date of manufacture when stored properly, for certified and non-certified garments.
Store cool (between 40º and 90º F), dry and well ventilated, away from direct sunlight or UV exposure, with the closures open.
A full visual inspection upon receipt, prior to donning, after a garment is worn and before it is made available for reuse, and annually.
Each cleaning cycle should be documented in the inspection log.
Designed for multiple uses, single exposure. Contaminated garments should be discarded.
Retired garments that are not contaminated may be labeled and used "For Training Use Only."
Construction, certified-ensemble, sizing and care details for the DuraChem 500 family.
| All styles | |
|---|---|
| Fabric | DuraChem® 500 fabric, which does not contain PFAS chemistry |
| Hood | Attached Hood with Sure-Fit® Respirator Face Piece Seal |
| Feet & ankles | Attached Sock Booties with Splash Guards, Hook & Loop Fasteners at Ankles |
| Fabric colors | Khaki, Navy (D5H457 6E: Khaki) |
| Origin | Made in USA |
| Certified -94 / -94BC styles | |
| Garment | Non Encapsulating Coverall, designed to be vapor tight |
| Primary material | Kappler DuraChem® 500 chemical barrier fabric |
| Closure |
|
| Gloves | Permanently Attached 22 mil Bromobutyl Gloves with Removable Touchscreen Overgloves |
| Seams | Heat Sealed / Taped: single needle lock stitch seam, nylon sewing thread, chemical barrier film tapes heat-sealed over the inside seam |
| Interface material | Butyl |
| Sock bootie | Integrated sock bootie of DuraChem® 500 material; separate outer safety boots must be worn |
| D5H457 6E coverall | |
| Construction | Front Entry Zipper, Double Storm Flaps with Hook & Loop Closure, Permanently Attached Gloves |
| Seams | Heat Sealed / Taped |
| Training suits D5S457 / D5S458 | |
| Construction | Front Entry Zipper (D5S457) or Rear Entry Zipper (D5S458), Single Storm Flap with Hook & Loop Closure, Permanently Attached Gloves |
| Seams | Serged |
| Certification | |
|---|---|
| Standard | NFPA 1990 (1994) Class 1 and Class 2, dual-certified for both CBRN and Hazmat response |
| Certified styles | D5H457-94, D5H457-94BC, D5H458-94, D5H458-94BC |
| Outer gloves | Outer gloves must be worn for Class 1 and 2 compliance; for Class 1 applications, don the provided outer glove |
| Respiratory protection | |
| SCBA | Certified ensembles must be used with NIOSH CBRN approved SCBA |
| Certified face pieces |
|
| Footwear & head | |
| Boots tested | OnGuard HazMax #87012 or Tingley #82330 |
| Outer boot footwear | Must measure at least 140mm (5.5in) high and be certified to NFPA 1951, 1971, 1991, 1992, 1994, or 1999 |
| Helmet | The DuraChem® 500 ensemble will accommodate a Type 1 Class G helmet |
| Integrity & marking | |
| Pressure test | Adaptor AKM007 with pressure test kit AKMOC; vapor-tight integrity verified using ASTM F1052 |
| Taping | Adhesive tape may not be used as a means to create interfaces between ensemble elements. Ensembles may be marked with Kappler ChemTape®. |
| Sizes | |
|---|---|
| Stocked sizes | SM/MD, LG/XL, 2X/3X, 4XL (all seven styles) |
| Glove sizing | Small and Medium: SM/MD · Large and X-Large: LG/XL · 2X-Large: 2X/3X, 4X |
| Packaging | |
| Case | 1 /cs |
| Case weight |
|
| Use | |
|---|---|
| Service life | Multi-use, single exposure and launderable up to five washes if not contaminated. Not designed to be repaired; contaminated garments should be discarded. |
| Exposure limits | This garment should not be immersed in chemicals. This garment should not be exposed to continuous hazardous liquid chemical splash or deluge. |
| Closure | The Zipper/Closure system has not been tested for permeation resistance. |
| Thermal | CAUTION: These garments are designed for protection of personnel against short duration thermal exposures. Do not use for firefighting applications. Minimize exposure to open flame or intense heat. |
| Laundering & decon | |
| Washing |
|
| Decontamination | Water and mild household dishwashing liquid only |
| Storage | |
| Shelf life | Predicted storage life of 10 years from the date of manufacture when stored properly, based on accelerated aging studies; applies to certified and non-certified garments |
| Conditions | Cool (between 40º and 90º F), dry, well-ventilated location, away from direct sunlight or UV exposure, with the closures in the open position |
| Inspection | Upon receipt, prior to donning, after a garment is worn and before reuse, and annually |
Features, chemical test battery, chemical warfare agent data and certified face pieces.
Guide · PDFA concise reference to the protective clothing standards consolidated under NFPA 1990, including Class 1 and Class 2.
Statement · PDFPFAS and PPE: what it means to the end user, including DuraChem 500.
Tell us which styles and sizes your team needs, certified, Berry Compliant or training, and we'll put together a quote for your DuraChem 500 suits and pressure-test gear.
