Matching the Garment to the Hazard

Important considerations for selecting protective apparel that aligns with real world risks.

• By Kevin Endres, Ph.D., Khyati Vyas, Mark Tartaglia
• Oct 15, 2025

In the world of occupational health and safety, selecting the right personal protective equipment (PPE) is critical—but not all PPE is created equal. When matching the right garment to the specific hazards workers face, safety professionals must weigh important criteria such as fabric barrier properties, garment seam type, design, and features to consider for protective garment selection.  

Across various industries and applications, workers face a wide array of hazards. Choosing a garment that is over-protective can lead to unnecessary costs and discomfort, while under-protection can result in serious injury or worse. The goal is to find the right balance—garments that are “fit for purpose” based on a thorough understanding of the risks involved. 

Start with a Hazard Risk Assessment 

The foundation of any PPE decision is a comprehensive job hazard risk assessment. This process identifies the types of hazards associated with a task or process, such as: 

• Thermal hazards: Including arc flash, flash fire, or hot surfaces. 
• Particulate hazards: Such as asbestos, lead dust, or combustible dust. 
• Chemical hazards: Including acids, bases, solvents, or toxic chemicals. 
• Biological hazards: Like bloodborne pathogens or infectious agents. 
• Physical hazards: Such as noise, extreme temperatures, tight spaces, protruding equipment, slips, trips, or falls 

Each of these hazards requires specific garment barrier attributes. For example, thermal hazards may necessitate flame-resistant (FR) garments, while chemical hazards can require garments with high chemical resistance.  

In addition to hazard identification, the risk assessment needs to include a comprehensive understanding of the task being performed and expected environmental conditions to anticipate the garment contact exposure scenario (physical state, quantity, concentration, duration, direction).  

It’s important to note that PPE outside of garments should also be selected by the same rigorous assessment process and work together as an ensemble. 

The Hierarchy of Controls 

Safety managers should apply the hierarchy of controls to manage hazards identified—prioritizing elimination, substitution, engineering, and administrative controls before using PPE. PPE serves as the last line of defense and can help mitigate remaining exposure risks or serve as a temporary measure while higher-level controls are being implemented. This context is essential for understanding why the following garment features matter. 

Primary Consideration for Selection 

Fabric can be engineered such that there could be multiple materials, fibers, coatings, or layers to help provide the wearer with enhanced protection against various hazards.  

For fabric selection of chemical protective garments, two key concepts to understand are the difference between permeation and penetration.  

• Permeation: The process by which a chemical passes through a fabric at the molecular level. This is the preferred method for the evaluation of hazardous liquids, vapors and gases and is especially important for garments used in chemical environments. 
• Penetration: The movement of substances through pores or seams in the fabric. This is the preferred method for measuring protection from particle and biological hazards. 

 Always check for chemical permeation data from garment suppliers. This data helps ensure that the fabric can withstand the specific substances present. For example, a garment that resists acids may not be effective against organic solvents.  

Additional considerations for fabric selection can include: 

• Durability: Resistance to abrasion and stress can help ensure that your garment maintains its protective qualities and minimizes hazard penetration. 
• Comfort: Fabric weight and breathability can impact temperature regulation and moisture transmission; lighter-weight, more breathable fabrics may help reduce heat stress.  

Seams: The Hidden Vulnerability 

Even the best fabric can be compromised by poor seam construction. Seams are often the weakest point in a garment, and different seam types offer varying levels of protection: 

• Serged (Stitched) seams: Basic stitching, suitable for low-risk environments. 
• Bound seams: Tightly stitched, reinforced with outer binding of fabric for added durability and protection. 
• Taped seams: Stitched seam sealed with heat-sealable tape provides enhanced protection and durability to block liquids and particles. 
• Welded seams: Fused without stitching for similar protection as taped seams. 

The choice of seam should align with the hazard assessment. For example, in environments with splash risks, taped or welded seams are preferable to serged or bound seams, as they offer the highest level of protection. 

Garment Design: Beyond the Coverall 

Design plays a dual role in protection and usability. A well-designed garment not only protects the worker but also supports comfort and mobility. Key design considerations include: 

• Coverage: The level of coverage should match the exposure risk. Options range from accessories like hoods and boot covers to encapsulating full-body suits. 
• Fit and mobility: Garments should allow for a full range of motion without compromising protection. Poorly fitting garments can lead to gaps in coverage or hinder job performance.
• Comfort: Choosing the optimal garment style to meet protection needs while not being over-protected can help improve compliance and productivity and, in certain instances, can also help reduce heat stress and fatigue. For example, a sleeved apron (when deemed sufficient protection for the task) is generally more comfortable than a full coverall.  

Check with garment manufacturers to understand the range of available garment styles and how they apply to different job roles. 

The Benefits of a Tailored Approach 

Selecting the most appropriate garment for the job offers several key benefits: 

• Enhanced safety: Garments that match the hazard profile help reduce the risk of injury. 
• Improved comfort: Workers are more likely to wear PPE correctly and consistently when it fits well and feels comfortable. 
• Cost savings: Avoiding over-specification prevents spending on high-end garments that may not be needed. 
• Operational efficiency: Garments that support mobility and functionality help workers perform tasks more effectively. 

Conclusion 

Protective garments are a vital component of workplace safety, but they must be selected with care. By conducting a thorough hazard risk assessment, understanding fabric and seam technologies, and considering garment design, safety professionals can make informed decisions that protect workers while balancing comfort and functionality. The most appropriate garment for the job is not always the one with the highest level of protection, but rather the garment that best addresses the full requirements for the task.  

This article originally appeared in the October 2025 issue of Occupational Health & Safety.