A guide to the best acid and alkali resistant workwear for the chemical industry

Here’s a technical guide to surface coating treatments for polyester-cotton workwear fabrics targeting acid/alkali resistance in chemical environments, balancing protection, durability, and wearability:

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Why Coat Polyester-Cotton Blends?

Poly-cotton (e.g., 65/35 or 50/50 blends) offers breathability and comfort but lacks inherent chemical resistance. Surface coatings bridge this gap by:

• Creating a chemical barrier without sacrificing fabric flexibility

• Enhancing liquid repellency (critical for splash protection)

• Preserving tear strength and abrasion resistance

Click to read the details of acid and alkali resistant protective clothing

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Top 4 Coating Technologies for Acid/Alkali Resistance

1. PU (Polyurethane) Coatings

• Mechanism: Forms microporous film blocking liquid penetration

• Acid/Alkali Performance:

  • ✓ Resists ≤80% H₂SO₄/HCl & ≤80% NaOH

  • ✘ Fails against oxidizing acids (HNO₃), ketones

• Best For: Light-moderate splash protection (EN 13034 Type 6)

• Brand Examples: HAIYUAN， HengLu®, Archroma Smartrepel Hydro

2. PTFE (Teflon®) Laminates

• Mechanism: Non-stick fluoropolymer layer bonded to fabric

• Performance:

  • ✓ Broad resistance (acids, alkalis, solvents)

  • ✓ Highest durability (>50 industrial washes)

• Trade-off: Reduced breathability (+5°C heat stress)

• Use Case: High-exposure areas (e.g., tank cleaning)

• Leaders: Gore® Chempak®, Saint-Gobain Norton ChemLam

3. Fluorocarbon (FC) Finishes

• Mechanism: Nano-scale fluoropolymer chains repel liquids

• Advantages:

  • Maintains fabric drape/breathability

  • Cost-effective for disposable/low-reuse gear

• Limits:

  • Degrades after 10-20 washes

  • Avoid >70°C cleaning

• Top Suppliers: Nicca Chemical NF-501, Huntsman PHOBOL® XAN

4. Hybrid Nanocomposite Coatings

• Innovation: PU + SiO₂/ZnO nanoparticles + fluorochemicals

• Benefits:

  • 2X longer permeation breakthrough vs. PU alone (ASTM F739)

  • UV resistance for outdoor chemical work

• Emerging Tech: TopChim Fibrocoat AS7, Solvay PHOBOL EXTENDER™

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Critical Coating Performance Metrics

⚠️ Real-World Validation: Always test with YOUR facility’s chemicals (e.g., 50% NaOH or 30% H₂SO₄) – generic ratings can mislead.

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Coating Application Methods

Padding (Most Common)

• Fabric dipped in coating bath → squeezed through rollers → cured at 160-180°C

• Pros: Uniform coverage, high throughput

• Cons: Penetrates fabric, reducing breathability

Lamination

• PTFE/PU film bonded to fabric surface via adhesive

• Pros: Maximum barrier, no chemical penetration

• Cons: Stiff hand feel, higher cost

Spray Coating

• Robotic spray on finished garments (seams, chest, sleeves)

• Pros: Targeted protection, minimal weight gain

• Cons: Labor-intensive, patchy coverage risk

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Workwear Design Essentials for Coated Fabrics

1. Seam Engineering:

   • Taped seams (Type 3 EN 14605) with PU thermotape

   • Double-stitched + overlock to prevent wicking

2. Reinforcement Zones:

   • Extra coating on knees, elbows, chest (200 g/m² vs. 150 g/m² base)

3. Closure Systems:

   • Chemical-resistant zippers with storm flaps (YKK® Natulon®)

   • Hook-and-loop avoided (traps contaminants)

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Leading Treated Fabric Suppliers

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Maintenance Protocol

• Washing: pH-neutral detergents (<40°C), no bleach

• Drying: Tumble dry low (<60°C) – high heat delaminates coatings

• Rejection Criteria:

  • Stiffness increase >40% (coating degradation)

  • Water repellency <70% (Bundesmann test)

  • Visible cracks under 10X magnifier

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Cost vs. Performance Trade-offs

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Key Takeaway:

“For most chemical operations, dual-action PU/FC coatings (e.g., Rudolf’s Bionic-Finish® ECO) offer the best balance. In high-risk zones (e.g., HF acid), PTFE-laminated fabrics are non-negotiable. Always pair coatings with sealed seams – an unsealed stitch is your weakest link.”

Include coating thickness cross-section diagrams and permeation test reports from suppliers during procurement audits.