NFPA 1990 (1991) apparel for chemical flash-fire protection
A single suit with three-way protection: chemical, flash-fire and radiant heat. Frontline 500 combines broad chemical holdout with flame resistance and radiant heat protection, in a gas-tight vapor suit certified to NFPA 1990 (1991), including the optional Flash Fire and Liquified Gas requirements. A 'multi-use, single exposure' garment that provides an economical NFPA alternative to expensive reusable suits.
Frontline garments are designed for chemical flash-fire protection for escape only in the event of a chemical flash fire. Do not use for firefighting applications.
Every Frontline 500 style is a gas-tight, silver vapor total encapsulating suit with the same construction. The difference is the entry: front entry or rear entry, each with an AquaSeal® gas-tight zipper.
Certified models F5H582-91 and F5H583-91.
IllustrationFrontline® 500 NFPA 1990 (1991) Certified Vapor Total Encapsulating Suit with a Front Entry AquaSeal® Gas-Tight Zipper.
IllustrationFrontline® 500 NFPA 1990 (1991) Certified Vapor Total Encapsulating Suit with a Rear Entry AquaSeal® Gas-Tight Zipper.
Reading the style number
Frontline 500 offers proven three-way protection: broad chemical holdout, plus flame resistance and radiant heat protection for the additional hazards encountered in a chemical flash fire.
Frontline 500 provides excellent holdout for the ASTM F1001 battery and many additional chemicals, and meets NFPA 1990 (1991), including base requirements plus optional Flash-Fire and Liquified Gas requirements.
Frontline 500 meets the requirements for flame resistance in accordance with ASTM F1358.
Frontline 500 has been tested for thermal protective performance (TPP) in accordance with ISO 17492, Clothing for Protection Against Heat and Flame, and showed a TPP value of 32.
Frontline 500 has been tested in accordance with ASTM F1930, Standard Test Method for Evaluation of Flame Resistant Clothing for Protection Against Flash Fire Simulations Using an Instrumented Manikin. The Frontline 500 ensemble garment indicated 0% body burn after a six-second burn test. Kappler's focus on user survivability included Pyroman Thermal Manikin testing in addition to the NFPA 1990 (1991) Chemical Flash Fire Option.
Frontline garments are designed for chemical flash-fire protection FOR ESCAPE ONLY in the event of a chemical flash fire.
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.
Kappler's AntiFog Expanded-View Visor is standard on all gas-tight suits, including NFPA-certified styles. On Frontline 500 it sits in a suit built around a gas-tight zipper, a field-replaceable glove system and heat-sealed seams.
Comparison shows AntiFog vs. Standard Visor.
The expanded-view AntiFog visor system enhances responder safety. Three layers make up the visor:
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2
3
4
5
6
AquaSeal® gas-tight zipper, shown closing under the storm flaps
2 mil anti-fog treated inner, 40 mil FR PVC middle and 5 mil FEP outer, with an additional FEP overlay.
Makes sizing easy to see, and a quick QR code scan provides complete chemical data plus extensive suit details.
Highly flexible, making donning, doffing and pressure testing much easier. Polyurethane coated with heavy duty molded nylon teeth and stainless steel slider components, protected by double storm flaps with FR hook & loop closure.
Field-replaceable, eliminating the problem of inner glove inversion, plus removable overgloves. Three layers: PE/EVOH laminate inner, 35 mil butyl middle, Kevlar® or Kevlar® and leather tip outer. Connected to the sleeve via a steel clamp/PVC ring.
An expanded-back encapsulating cut, with reinforcement at the knees.
An integrated sock bootie of Zytron® 500 material. Separate outer safety boots must be worn over it.
Impact resistant plastic body and silicon rubber diaphragm, attached by a mechanical screw compression seal, with splash resistant covers of the primary garment material.
Single needle lock stitch with nylon thread; chemical barrier film tape heat-sealed over the inside seam. Heat Sealed / Taped on Inner and Outer Seams.
Frontline 500 provides excellent holdout for the ASTM F1001 battery and many additional chemicals, with warfare agent data alongside.
| Chemical Agent | Minutes | Criteria |
|---|---|---|
| Bis (2-chloroethyl) sulfide (Mustard:HD) | >480 | 4.0 ug/cm2 |
| Isopropyl methylfluorophosphonate (Sarin:GB) | >480 | 1.25 ug/cm2 |
| O-ethyl S-(2-diisopropylaminoethyl) methylphosphonothiolate (Nerve:VX) | >480 | 1.25 ug/cm2 |
Industrial chemical testing was conducted in accordance with ASTM F739 with normalized breakthrough times reported in minutes. Chemical Warfare Agent testing was conducted in accordance with MIL-STD-282 and/or NFPA 1990 (1991) with breakthrough times reported based on total cumulative permeation.
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, with exception of Pyroman full-body manikin test.
Permeation based on ASTM F739, results in minutes. Sources for all chemical test data are independent laboratories; tests were performed under laboratory conditions on material samples, not actual garments. Ask us for results on a specific chemical.
| Chemical Name | CAS | Result |
|---|---|---|
| Bromine | 7726-95-6 | 80 |
| Chlorosulfonic Acid | 7790-94-5 | >480 |
| Hydrochloric Acid, 37% | 7647-01-0 | >480 |
| Hydrofluoric Acid 48% | 7664-39-3 | >480 |
| Hydrogen Peroxide, 30% | 7722-84-1 | >480 |
| Nitric Acid, 70% | 7697-37-2 | >480 |
| Oleum (27% SO3) | 8014-95-7 | >480 |
| Sodium Hypochlorite, 13% | 7681-52-9 | >480 |
| Chemical Name | CAS | Result |
|---|---|---|
| Benzene | 71-43-2 | >480 |
| Carbon Tetrachloride, 99.5% | 56-23-5 | >480 |
| Diesel Fuel Ultra Low Sulfur | Mixture | >480 |
| Gasoline | 8006-61-9 | >480 |
| JP 8 Jet Fuel | mixture | >480 |
| Methyl Ethyl Ketone | 78-93-3 | >480 |
| Methyl tert Butyl Ether | 1634-04-4 | >480 |
| Trichloroethylene | 79-01-6 | >480 |
| Chemical Name | CAS | Result |
|---|---|---|
| Acrolein | 107-02-8 | >480 |
| Acrylonitrile | 107-13-1 | >480 |
| Boron Trifluoride | 7637-07-2 | >480 |
| Hydrogen Fluoride Gas 99% | 7664-39-3 | >480 |
| Hydrogen Sulfide 100% Vapor | 7783-06-4 | >480 |
| Methyl Hydrazine 98% | 60-34-4 | >480 |
| Nitrogen Dioxide | 10102-44-0 | >480 |
| Phosphorous Oxychloride | 10025-87-3 | >480 |
| Titanium Tetrachloride | 7550-45-0 | >480 |
| Toluene-2,4-diisocyanate | 584-84-9 | >480 |
Vapor protective garments totally enclose the wearer and isolate the wearer from exposure to outside gases and vapors. Frontline 500 must be used in combination with additional PPE.
Separate NIOSH approved full-face respiratory protection such as SCBA, or an external breathing air supply with escape bottle. Certified ensembles must be used with NIOSH CBRN approved SCBA. The SCBA tested with this ensemble was the Scott AV 3000 HT Sure Seal.
The OnGuard HazMax #87012 or Tingley #82330 boot must be worn over the integrated bootie for compliance to NFPA 1990 (1991) - 2022.
To connect to an external supplied airline system, these garments must be equipped with the appropriate NIOSH approved garment pass-through.
The wearer should consider wearing inherently flame resistant, woven clothing, with long sleeves and pants under this garment.
Assisted donning
Kappler's pressure test procedure mirrors ASTM F1052, Standard Test Method for Pressure Testing Vapor Protective Ensembles, and requires an external air supply.
Inflate the garment to a pressure of 5.0 inches of water column, then reduce the air pressure to 4.0 inches of water column. After four (4) minutes, read the air pressure gauge. If the pressure has not dropped below 3.2 inches water column, the garment has passed.
This garment is designed for multiple uses, single exposure. It is not designed to be repaired. Contaminated garments should be discarded.
The only decontamination solutions to use with this garment are water and mild household dishwashing liquid. Retired garments that are not contaminated may be labeled and used "For Training Use Only."
A predicted storage life of 10 years from the date of manufacture when stored properly, based on accelerated aging studies. Store away from direct sunlight or UV, in a cool (40º–90º F), dry, well-ventilated location, with the closures in the open position.
Line-level construction, test and sizing data that applies to every Frontline 500 style.
| Garment | |
|---|---|
| Primary material | Kappler Frontline® 500 chemical barrier fabric |
| Fabric color | Silver |
| Garment type | Vapor Total Encapsulating Suit · Expanded Back |
| Entry | Front entry (F5H582-91) or rear entry (F5H583-91) AquaSeal® Gas-Tight Zipper |
| Seams | Single needle lock stitch seam, nylon sewing thread; chemical barrier film tapes heat-sealed over the inside seam. Heat Sealed / Taped on Inner and Outer Seams. |
| Reinforcement | Knee Reinforcements |
| Label | SMART™ label with QR code |
| Visor | |
| Visor system | Expanded View AntiFog Visor System with Additional FEP Overlay |
| Layers | 2 mil anti-fog treated inner, 40 mil FR PVC middle and 5 mil FEP outer |
| Closure | |
| Zipper | AquaSeal® gas-tight polyurethane coated zipper with heavy duty molded nylon teeth; stainless steel slider components |
| Flap | Double Storm Flaps with FR Hook & Loop Closure, composed of garment material |
| Permeation | The Zipper/Closure system has not been tested for permeation resistance. |
| Gloves, boots & valves | |
| Glove system | Field Replaceable 2N1® Glove System and Removable Overgloves |
| Glove layers |
|
| Glove attachment | Steel clamp/PVC ring via mechanical screw compression |
| Footwear | Attached Sock Booties with Splash Guards: integrated sock bootie of Zytron® 500 material; separate outer safety boots required |
| Exhaust valves | 2 Exhaust Valves: impact resistant plastic valve body, silicon rubber diaphragm, mechanical screw compression seal, splash resistant covers of the primary garment material |
| Certification | |
|---|---|
| NFPA | Meets requirements of NFPA 1990 (1991), including base requirements plus optional Flash-Fire and Liquified Gas requirements |
| Certified models | F5H582-91 · F5H583-91 |
| Heat, flame and thermal | |
| TPP (ISO 17492) | 32 |
| Flame resistance | Meets the requirements for flame resistance in accordance with ASTM F1358 |
| Flash fire manikin (ASTM F1930) | 0% body burn after a six-second burn test (Frontline 500 ensemble garment). For escape only in the event of a chemical flash fire; do not use for firefighting applications. |
| Chemical | |
| Industrial chemicals | ASTM F739, normalized breakthrough times in minutes; ASTM F1001 Chemical Test Battery |
| Chemical warfare agents | MIL-STD-282 and/or NFPA 1990 (1991), breakthrough times based on total cumulative permeation |
| PFAS | Frontline 500 fabric does not contain PFAS Chemistry. PFAS found in FEP lens at this time. |
| Integrity | |
| Pressure test | Procedure mirrors ASTM F1052. Inflate to 5.0 inches of water column, reduce to 4.0; pass if the pressure has not dropped below 3.2 inches water column after four (4) minutes |
| NFPA 1990 (1991) requirements — Hazardous Materials and CBRN Operations Vapor and Liquid | |
|---|---|
| Chemical resistance vs garment fabric, seams, visors, gloves, boots | Permeation resistance 1 hr vs 21 industrial chemicals, 4 toxic industrial chemicals and agents mustard and soman |
| Chemical challenge level | Liquids 100 g/m2 Concentration · Vapors 100% |
| Chemical breakthrough criteria | ASTM F739 Cumulative (ug/cm2) 6.0 TIC's, 4.0 mustard, 1.25 soman |
| System tests | ASTM F1052 Pressure · MIST Inward Leakage PPDF > 488 · Shower > 60 min |
| Flame resistance and flame break open resistance | ASTM F1358 3 sec burn only · FTM 191A |
| Flash fire/thermal protection (standard requirement) | Optional requirement of the standard · ASTM F1358 12 sec burn · ASTM F2700 > 8 cal/cm2 |
| Comfort | N/A |
Requirements of the standard. Frontline 500 is certified to NFPA 1990 (1991) including the optional Flash-Fire and Liquified Gas requirements; flash-fire protection is for escape only.
| Sizing | |
|---|---|
| Available sizes | SM/MD, LG/XL, 2X/3X, 4XL |
| Combination sizing | Typically worn over other clothing, Kappler's garments are designed so that "combination sizes" comfortably fit the vast majority of users. |
| Storage & use | |
| Storage life | Predicted storage life of 10 years from the date of manufacture when stored properly, based on accelerated aging studies |
| Storage conditions | Away from direct sunlight or UV exposure; cool (between 40º -90º F), dry, well-ventilated location; in original boxes, in bags, or on hangers, with the closures in the open position |
| Use | Multiple uses, single exposure; not designed to be repaired |
| Decontamination | Water and mild household dishwashing liquid only |
Features, heat, flame and thermal test data, and chemical test data.
StandardsA concise reference to the protective clothing standards consolidated under NFPA 1990.
PFASWhat PFAS means to the end user of Kappler protective garments.
Tell us which style you need, front or rear entry, with sizes and quantities, and we will come back with a quote.
