Steve Marnach, EMEA Training Manager & Specialist Critical Environments, DuPont Personal Protection, explains why taping PPE interfaces is critical for maintaining chemical barrier integrity and outlines best practice to consider when selecting and applying chemical barrier tape.
Exposure to hazardous chemicals presents a risk to many workers, from emergency responders and laboratory technicians to oil rig operators and maintenance crews. Chemical protective clothing, such as coveralls, gloves, boots, and facemasks, is designed to provide barrier protection. However, the integrity of the entire system is only as good as its weakest link. Seams, closures, and interfaces between different items of protective clothing are points of vulnerability.
While most workers understand the need to wear the correct PPE, taping during donning is often overlooked. Incorrect application, using the wrong type of tape, or simply not taping at all, compromises the effectiveness of the chemical barrier. No matter how high-performance your PPE is, it will fail if interfaces are not properly sealed. It’s time to give taping the attention it deserves.
Maintaining barrier integrity
Chemical protective clothing is designed to provide a barrier between workers and hazardous substances, but its effectiveness depends on the integrity of the entire PPE system. We all know that the smallest rip or tear in a protective coverall or glove compromises its effectiveness, but the fabric is not always the point of failure. Often, it is the interfaces where different PPE components meet. Seams, closures and interfaces – such as where gloves meet sleeves, hoods connect to respirator masks, or boots meet coveralls – can all become entry points for hazardous substances if not properly sealed.
These interfaces are exposed to movement, pressure, and environmental conditions during work tasks, making them particularly susceptible to gaps or shifts in positioning. Even a small opening can allow liquid chemicals, aerosols, or contaminated dust to bypass the garment’s protective barrier and reach the skin. For workers operating in environments where they may encounter corrosive substances, toxic industrial chemicals, or hazardous particulates, the consequences of such exposure can be serious.
Taping plays a critical role in maintaining the integrity of the PPE system by reinforcing these vulnerable connection points. By sealing interfaces between garments and other protective equipment, tape helps create a continuous protective barrier around the wearer. This helps to ensure that PPE performance is maintained across the entire protective ensemble, significantly reducing the risk of chemical ingress and potential exposure.
In short, effective chemical protection is not just about selecting the right garment; it is about ensuring that every component works together as a single, sealed system.
Common taping mistakes
Despite its importance, taping is often poorly understood in practice. One common issue is a general lack of awareness. Workers may assume that once a chemical protective coverall is zipped closed, the garment itself provides complete protection. However, without properly sealed interfaces, hazardous substances can still reach the skin.
Another frequent problem is the use of unsuitable tape. General-purpose tapes such as duct tape are sometimes used because they are readily available on site. However, these products are not designed to provide chemical barrier performance. They can degrade, curl, or lose adhesion when exposed to chemicals or dust, creating pathways for contamination.
Application technique can also compromise protection. Long strips of tape wrapped tightly around wrists or ankles can crease as the wearer moves, forming folds that may channel liquids into the garment. Excessive tension can also restrict movement or complicate removal during doffing. In some cases, tape may even interfere with visibility or respirator seals if applied incorrectly. Effective taping requires both the right materials and the right technique.
Choosing the right tape
Selecting the correct tape is an important but sometimes overlooked element of PPE systems. Not all tapes are suitable for use in chemical protection environments, and the wrong choice can undermine the integrity of a protective garment.
One of the most important characteristics is chemical resistance. Barrier tape should be capable of resisting permeation by the chemicals likely to be encountered in the workplace. Otherwise, the tape itself may allow chemicals to pass through and reach the skin.
Adhesion performance is equally important. Tape must remain securely attached during a shift, even in environments where dust, humidity, or physical movement could affect its grip. If tape curls, lifts or loses tack, gaps may develop that allow hazardous substances to enter.
Ease of use is another practical consideration. Workers often need to apply tape while wearing gloves and other PPE, so tapes that are easily tearable and simple to position are preferable. Designs that require tools or the removal of backing paper can be difficult to manage under real working conditions.
Finally, visibility can contribute to safety. Tape that contrasts clearly with the garment makes it easier for supervisors to confirm that interfaces have been sealed correctly during safety checks.
These factors underline the importance of selecting tape specifically designed for chemical protective applications.
Applying tape correctly
Correct application is just as important as tape selection. A few simple principles can help ensure that PPE interfaces remain sealed while still allowing the wearer to move and work safely.
PPE components should be properly fitted before taping begins. Tape is intended to seal interfaces, not to compensate for poorly fitting equipment.
When applying tape, short overlapping pieces are generally more effective than long continuous strips. Smaller sections conform more easily to the contours of the body and reduce the likelihood of creases forming. Care should also be taken to avoid excessive tension. Tape applied too tightly around wrists or ankles can restrict movement and may complicate removal during doffing. The goal is to create a secure seal that remains comfortable and flexible throughout the task.
During doffing, tape should be removed carefully and disposed of appropriately, particularly if contamination is possible. Such straightforward practices can significantly improve the integrity of chemical protective clothing systems.
Sourcing purpose-designed tape
PPE manufacturers have developed tapes specifically for chemical protective applications. These products aim to complement the barrier performance of protective garments while remaining practical to use in the field.
One recent introduction is Tychem® 6000 Tape from DuPont, which has been specifically developed for use with chemical protective clothing. The tape is designed to provide a permeation barrier of at least 30 minutes against a range of chemical hazards, including organic and inorganic compounds.
The bright yellow tape is hand-tearable for ease of application and designed to remain flat during placement, helping users achieve a consistent seal. Designed as Category I PPE under Regulation (EU) 2016/425, this tape is suitable for use with Category III chemical protective garments.
While different products may offer different features, the broader lesson for safety professionals is clear: accessories such as tape should be selected with the same care as the garments themselves.
Closing the gaps
Ensuring that workers are fully protected from exposure to hazardous chemicals in the workplace relies on much more than specifying the right type of protective clothing. How the entire ensemble works together also requires attention, especially where there are gaps between different items.
Taping helps close these gaps, creating a continuous protective barrier around the wearer. When appropriate tape is selected and applied correctly, it reinforces the integrity of the entire PPE system.
For health and safety professionals, raising awareness of correct taping practices can be an important step in reducing exposure risks. By paying attention to tape selection and training workers in correct application, organisations can help close the gaps in chemical PPE protection – ensuring equipment performs as intended when workers need it most.
For more guidance about correct PPE selection, visit: https://www.safespec.dupont.co.uk/
