KAPPLER DuraChem 500 Operation manual

Certied Models NFPA 1990 (1994) – 2022 Edition
Class 1 and 2 • D5H457-94 • D5H458-94
User Information
for DuraChem® 500
Protective Ensemble
for Hazardous Materials
Emergencies and CBRN
Terrorism Events
RM 31655 REV 01-2023

THIS INFORMATION PACKET MAY NOT BE REMOVED EXCEPT
BY THE END USER
Kappler, Inc.
P.O. Box 490 | 115 Grimes Drive
Guntersville, AL 35976
256-505-4005 Phone
800-600-4019 Toll free
256-505-4151 Fax
[e-mail]
User Information for
DuraChem 500 Protective Ensemble
Certified Models
NFPA 1990 (1994) – 2022 Edition
Class 1 and 2
22-KAP-113

CONTENTS
Safety Considerations..............................................................................................................................1
Safety Symbols Used In This Manual...................................................................................................1
Warnings and Limitations ......................................................................................................................2
Additional Equipment ��������������������������������������������������������������������������������������������������������������������������������������������� 3
Wearers Must Be Physically Fit ���������������������������������������������������������������������������������������������������������������������������� 3
Always Use the Buddy System ����������������������������������������������������������������������������������������������������������������������������� 4
Manage and Prevent Heat Stress������������������������������������������������������������������������������������������������������������������������ 4
Chemical Permeation Resistance ������������������������������������������������������������������������������������������������������������������������ 5
Static Electricity����������������������������������������������������������������������������������������������������������������������������������������������������������� 5
Avoid Continuous Exposure����������������������������������������������������������������������������������������������������������������������������������� 6
Sock Booties���������������������������������������������������������������������������������������������������������������������������������������������������������������� 6
Provide Hearing Protection ������������������������������������������������������������������������������������������������������������������������������������ 6
Communications �������������������������������������������������������������������������������������������������������������������������������������������������������� 6
Inspection of the Garment .....................................................................................................................7
Full Visual Inspection ..............................................................................................................................7
Returning the Garment ...........................................................................................................................8
Storage Life and Storage Conditions..................................................................................................8
Storage Life..........................................................................................................................................................8
Storage Conditions ............................................................................................................................................9
Closure Lubricants ...................................................................................................................................9
Marking Recommendations and Restrictions ...................................................................................9
Respirator Consideration for Ensembles ...........................................................................................9
Sizing Considerations ........................................................................................................................... 10
Donning the Garment............................................................................................................................10
Dong the Garment.............................................................................................................................. 12

Interface Issues....................................................................................................................................... 12
Decontamination and Cleaning of Chemical and Biological Contamination ......................... 13
Decontamination Solutions.............................................................................................................................13
Field Decontamination.....................................................................................................................................13
Decontamination before Reuse.......................................................................................................... 14
Maintenance and Cleaning.............................................................................................................................14
Retirement Considerations.................................................................................................................. 15
Disposal .................................................................................................................................................... 16
Warranty information ............................................................................................................................. 16
Appendix A - Technical Data Package ............................................................................................. 17
NFPA 1994 Class 2 Performance Data ............................................................................................. 17
Sizing Information .................................................................................................................................. 17
Garment Material and Component Descriptions........................................................................... 17
Garment Material...............................................................................................................................................17
Elastometric Interface Material ......................................................................................................................18
Glove Material And Assembly........................................................................................................................18
Sock Bootie Material ........................................................................................................................................18
Physical Foot Protection..................................................................................................................................18
Zipper/Closure Type and Material ..................................................................................................... 19
Material Seam Types and Composition............................................................................................ 19
Seam Material - Garment................................................................................................................................ 19
Seam Material - Interface Material............................................................................................................... 19
Seam Material - Glove..................................................................................................................................... 19
Seam Material - Footwear.............................................................................................................................. 19
Seam Material - Garment Closure............................................................................................................... 20

Head Protection Accommodated with this Garment...................................................................20
Durachem® Glove Sizing Chart .........................................................................................................20
Appendix B - Garment Sizing Chart .................................................................................................. 21
Appendix C - DuraChem® 500 Inspection Log.............................................................................22

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SAFETY CONSIDERATIONS
It is the user’s responsibility to read, understand and follow the information in this
manual and on Kappler’s website, www.kappler.com and all applicable Federal,
state and local occupation safety and health statutes. For users outside the United
States, please consult national or other applicable personal protective equipment
regulations. Proper use should be consistent with NFPA 1500, Standard on Fire
Department Occupational Safety and Health Program, and 29 CFR 1910.132.
The Authority Having Jurisdiction (AHJ) responsible for approving equipment
must comply with the requirements of NFPA 1891 for the selection, care, and
maintenance of protective ensembles and elements.
SAFETY SYMBOLS USED IN THIS MANUAL
While reading this manual, you will come across a number of warnings concern-
ing some of the risks and dangers you may face while using the device. These
warnings contain “signal” words that will alert you to the degree of hazard you
may encounter. These words, and the hazards they describe, are as follows.
warning
Indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.
caution
Indicates a potentially hazardous situation which, if not avoided,
could result in physical injury or damage to the product. It may
also be used to alert against unsafe practices.

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WARNINGS AND LIMITATIONS
NOTICE
Indicates additional information on how to use the garment.
caution
This garment must be used in combination with additional PPE,
which include the following:
Separate full-face respiratory protection such as a self-contained
breathing apparatus (SCBA) or an external breathing air supply
(airline system with garment pass-through) with escape bottle.
NFPA compliant garments must use NIOSH CBRN approved SCBA.
Separate foot and lower leg protection such as chemical
protective boots.
warning
There are uses, environments, and chemicals for which these
garments and/or fabrics are unsuitable. It is the responsibility of
the user to review available data and verify that the garment and/
or fabric is appropriate for the intended use and meets all
specified and/or industry standards.

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Additional Equipment
Additional personal protective equipment that might also be considered includes:
●Head protection.
● Hearing protection may be required due to high levels of external
noise or high noise levels generated by supplied air systems.
● Other protective equipment that may be warranted based on
the situation.
Wearers Must be Physically Fit
Garments should only be worn by persons who are in good
physical condition. Working in a totally encapsulating garment
is strenuous. In an emergency situation or hot environment, the
wearer may experience heat stress. Persons who show
symptoms of heat stress such as nausea, dizziness, or excessive
heat build-up should leave the work area immediately and do
the garment as quickly as possible. Persons in doubt about their
physical condition should check with a physician before wearing
these garments.
If any of the following symptoms develop during use of this
garment, immediately leave the hot zone, undergo field
decontamination (if exposed), and do the garment:
●Fever
●Diculty breathing
●Nausea
●Excessive tiredness
caution
continued

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Always Use the Buddy System
Never work in this garment alone. A minimum of two people should enter con-
taminated areas together. It is important to have someone available to assist in
the event of an emergency. That person will require the same level of protection
as the person needing emergency assistance.
Manage and Prevent Heat Stress
This garment interferes with the natural regulation of body temperature. This can
lead to a rise in core body temperature and heat stress. The wearer should be
aware of the symptoms and treatment of heat stress. The wearer can take several
steps to limit and/or prevent heat stress, such as use of a cooling system, and
working in accordance with a conservative work/rest schedule. The maximum
time the garment can be worn depends on such variables as the air supply, ambi -
ent condition, climate inside the garment, physical and psychological condition of
the wearer, work rate and work load. The TLV™ pocket guide from the American
Conference of Governmental Industrial Hygienists (ACGIH, Cincinnati) provides
corrected heat stress limits for totally encapsulating garments. Similar information
is available on the federal OSHA website (www.OSHA.gov).
●Dizziness
●Numbness
●Any unusual odor or taste
●Eye or skin irritation
●Narrowing or dimming of vision
●Claustrophobia
●Loss of balance or orientation

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Chemical Permeation Data
Before using a garment in a chemical situation, consult the chemical permeation
data appropriate to the garment material. This information is to be used as a
guide only. The permeation performance of any material depends on a number
of factors including chemical concentration, temperature, time and amount of
exposure, etc. Due to the large number of variables, it is impossible for all garment
materials to be tested against all chemicals, all combinations or mixtures, and all
temperatures at which the chemical might be encountered.
Chemical permeation tests are performed under laboratory conditions – not
actual workplace conditions. They address chemical breakthrough characteristics
and do not account for physical performance characteristics that aect barrier
such as abrasion, flex fatigue, puncture, tear, oxidative degradation, or degraded
performance due to previous contamination.
No single protective material will protect against all chemicals for all situations.
The best course of action is to test the primary garment materials against the
specific chemical hazard, at the temperature and in the concentrations to be
encountered. Kappler, Inc. will provide free swatches of primary garment materials
for testingand help arrange to have these tests performed.
Static Electricity
Under certain conditions, such as cold and dry weather, it is possible for garments
to build and discharge static electricity. Discharges are not normally dangerous
except in situations where generation of an electrical spark could ignite a flamma-
ble atmosphere. When working around flammable chemicals, steps to eliminate
potential static discharges should be used. In these situations, recommended
precautionary steps include raising humidity level of the work area and/or using
a commercial, anti-static application.

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Avoid Continuous Exposure
This garment should not be immersed in chemicals. This garment should not
be exposed to continuous hazardous liquid chemical splash or deluge. Do not
wade through liquid pools of hazardous chemicals if not necessary. Direct chem-
ical exposure to the garment should be as limited as possible. If exposed to
direct splash or deluge of hazardous chemicals, leave the area immediately and
decontaminate.
Sock Booties
The sock booties attached to this garment are designed to be worn inside outer
boots. These sock booties do not have sucient durability or slip resistance to
be worn as outer boots.
Provide Hearing Protection
If noise levels inside the garment exceed regulatory noise levels, hearing protec-
tion must be provided. Use hearing protection recommended by a safety pro-
fessional and which does not interfere with the operation or use of the garment.
Communications
A vapor-protective garment hampers communication. The use of a personal com-
munication system should be considered. Users should also consider the use of
hand signals to communicate during training, work, and for emergency situations
where respirators and totally encapsulating garments are worn.

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INSPECTION OF THE GARMENT
FULL VISUAL INSPECTION
To perform a full visual inspection:
● Choose a clean, dry area that is free of potential sources of snags,
tears and punctures.
●Mark suspected defects with colored adhesive tape.
●Visually inspect seams for tape lift or de-lamination.
● Visually inspect for surface damage or discoloration on material,
visor, gloves and closure.
● Check zipper closure for worn or damaged parts. Run your fingers
along the zipper length to feel for imperfections or separations.
caution
The garment should undergo a full visual inspection at the
following times:
●Upon receipt to ensure no damage has occurred
during shipment, OR prior to first donning of garment.
●After a garment is worn and before the garment is
made available for reuse.
●Annually. However, most performance properties of a
vapor-protective ensemble cannot be tested by the user in
the field.

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●Check function of zipper and slider.
Garments with visible holes, tears, rips, punctures, serious discoloration or abra-
sions should not be used.
Note any remarks in the Inspection Log. If the garment is unsuitable for use by
visual inspection, the garment maybe retired for training use after being perma-
nently labeled “For Training Use Only,” or disposed of properly.
RETURNING THE GARMENT
If a garment fails a visual inspection or pressure test, the garment may be returned
for inspection and possible replacement. Contact Kappler Inc. to authorize the
return. No contaminated garments will be accepted for return. Discoloration or
odors are evidence of contamination.
Garments being returned must be accompanied by the usage log and with a
letter stating that the garment has not been contaminated. Note: Charges may
be incurred. See warranty information.
STORAGE LIFE AND STORAGE CONDITIONS
Storage Life
Kappler’s Durachem® 500 garments have a predicted storage life of 10 years from
the date of manufacture when stored properly (see Storage Conditions), based
on accelerated aging studies. Storage life is defined as the period in which a
garment or element has undergone proper care and maintenance in accordance
with this instruction manual, but has not been used in either training or in response

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to actual incidents. The useable service life of the garment is dependent on
the chemicals exposed to the garment, the concentration of those chemicals,
the work environment, frequency of use, and the maintenance program. It is
the responsibility of the employer or purchaser to determine when the garment
should be taken out of service. It is recommended that garments be labeled and
retired to “Training Use Only,” if they do not pass the recommended visual and/
or pressure test inspections.
Storage Conditions
Garments should be stored away from direct sunlight, preferably in a cool, dry
location that is not subjected to extreme hot or cold conditions (between 40º -
90º F). Garments should be stored in their original boxes, in bags, or on hangers.
Garments should be stored with the zipper open.
CLOSURE LUBRICANTS
There are no lubricants recommended for the closure system.
MARKING RECOMMENDATIONS AND RESTRICTIONS
Ensembles may be marked with Kappler ChemTape.
RESPIRATOR CONSIDERATION FOR ENSEMBLES
Ensembles must be used with NIOSH CBRN approved self-contained breathing
apparatus (SCBA). The SCBA tested with this DuraChem® ensemble were:
Scott AV 3000 HT Sure Seal, MSA Ultra Elite, MSA GI, Dräger DHR 7000.
warning
Respirators have not been evaluated for chemical permeation
resistance consistent with the other ensemble elements..

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SIZING CONSIDERATIONS
The garment sizing chart should be used to determine accurate fit. The correct
size garment should be worn. See Appendix B pg� 21�
DONNING THE GARMENT
1. Conduct a brief visual inspection of the garment before beginning
donning procedure.
●Garment should be free of discoloration, or physical damage.
2. An assistant should help the wearer don the garment.
3. Remove all jewelry and personal items (pens, key rings, badges,
pagers, knife cases, etc.) that might damage the garment.
4. Check function of respirator and place nearby donning location.
5. Visually check size and condition of outer boots and place nearby
donning location.
6. Open garment zipper closure completely.
7. Read garment size label to assure proper fit.
to actual incidents. The useable service life of the garment is dependent on
the chemicals exposed to the garment, the concentration of those chemicals,
the work environment, frequency of use, and the maintenance program. It is
the responsibility of the employer or purchaser to determine when the garment
should be taken out of service. It is recommended that garments be labeled and
retired to “Training Use Only,” if they do not pass the recommended visual and/
or pressure test inspections.
Storage Conditions
Garments should be stored away from direct sunlight, preferably in a cool, dry
location that is not subjected to extreme hot or cold conditions (between 40º -
90º F). Garments should be stored in their original boxes, in bags, or on hangers.
Garments should be stored with the zipper open.
CLOSURE LUBRICANTS
There are no lubricants recommended for the closure system.
MARKING RECOMMENDATIONS AND RESTRICTIONS
Ensembles may be marked with Kappler ChemTape.
RESPIRATOR CONSIDERATION FOR ENSEMBLES
Ensembles must be used with NIOSH CBRN approved self-contained breathing
apparatus (SCBA). The SCBA tested with this DuraChem® ensemble were:
Scott AV 3000 HT Sure Seal, MSA Ultra Elite, MSA GI, Dräger DHR 7000.
warning
Respirators have not been evaluated for chemical permeation
resistance consistent with the other ensemble elements..

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8. Remove shoes. The sock booties on this garment are worn inside outer
chemical boots. These sock booties do not have adequate durability or
slip resistance to be worn over footwear as an outer covering.
9. While sitting, insert feet into garment legs and down into sock booties.
Stretch legs out to maximum extension while pulling garment up around
hips.
10.
Pull boot splash flaps up and don outer boots. Fold splash flaps down over
boots as far as possible.
11. Place one hand in the sleeve, pull garment sleeve to shoulder and place
hand into gloves.
12. Place other hand in sleeve and place hand into gloves.
13. Don respirator face piece and tighten head straps to secure.
14.
Pull hood over the head and secure, ensure proper fit between respirator
face piece and garment elastomeric face seal.
15.
Slowly close the zipper. After checking that the zipper is completely closed,
the flaps should be closed and sealed over the zipper.
16.
The user should squat down and expel the air inside the garment through
the face seal interface
17. For Class 1 applications, don the Nomex®/leather outer glove.

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DOFFING THE GARMENT
1. If the garment has been contaminated, or suspected of being contami-
nated, the wearer should continue to use his respirator until the garment
has been doed and removed.
2.
An assistant should help the wearer do the garment after field decontam-
ination. If the garment has been contaminated, the assistant should wear
protective clothing and respiratory equipment.
3. While the wearer stands, the assistant should open the closure and peel
the garment down and away from the wearer’s shoulders. The assistant
should help the wearer remove his arms from the sleeves.
4.
Lower the garment below the hips and sit down. Have the assistant remove
the boots, pull the garment o the legs, and remove the garment to a
remote location.
5.
Once the garment has been removed, the wearer can do the respiratory
face piece and harness.
INTERFACE ISSUES
The user should ensure respirators, boots and gloves, as applicable, are properly
interfaced. There are no special procedures for donning outer boots.
caution
Ensuring proper seal and fit between the respirator and the
face piece and the elastomeric face seal is critical to the overall
performance of the ensemble.

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DECONTAMINATION AND CLEANING OF CHEMICAL
AND BIOLOGICAL CONTAMINATION
Decontamination Solutions
The only decontamination solutions to use with this garment are water and mild
household dishwashing liquid. Do not use any oxidative, corrosive or reactive
decontamination solutions with this garment.
Field Decontamination
The purpose of field decontamination is to allow the wearer to do the garment
without being harmed by contaminants on the garment surface. Garments that
have been exposed to or that are suspected to have been exposed to chemical
or biological contamination should be field decontaminated before dong.
Additional cleaning, decontamination, a full visual inspection and a pressure test
are required before a garment may be reused.
1.
Leave the hot zone with adequate air supply for decontamination and
removal of the garment. The wearer should continue to wear the respirator
until the garment has been completely doed and removed from the area.
2. If the garment has been exposed or is suspected to have been exposed,
thoroughly scrub the garment using household dishwashing liquid and
soft scrub brushes, followed by a thorough rinsing in water.
3.
If possible, the excess rinse water should be removed from the garment by
individuals wearing gloves, liquid-splash protective clothing and respiratory pro-
tection. At a minimum, the excess rinse water on and near the closure assembly
should be removed with a dry cloth to ensure wearer is not exposed to chemical.

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DECONTAMINATION BEFORE REUSE
It is the responsibility of the safety professional having jurisdiction over usage
of the garment to determine whether the garment has been adequately decon-
taminated and can be safely re-used.
A qualified individual should develop and implement a decontamination proce-
dure for each of the chemicals to which the garment has been exposed. The
decontamination procedure should include complete information on the type of
contamination, as well as the level of contamination involved.
Contaminated garments should be discarded. Contaminated garments are not
suitable for training purposes.
Maintenance and Cleaning
● No reactive or corrosive decontamination solutions should be used
with this garment.
●Only water and mild household dishwashing liquid should be used as
decontamination liquids.
●Only garments that have been thoroughly cleaned and dried may be
considered for use.
caution
This garment is designed for multiple uses, single exposure. It is
priced to make disposal after use economically justified when
the eectiveness of decontamination is in question. This garment
is not designed for multiple exposures and multiple
decontaminations. This garment is not designed to be repaired.

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● Water and mild household dishwashing liquid should be used to clean
this garment.
●This garment may be scrubbed with a soft brush or hand towel,
thoroughly rinsed with clean, fresh water and air- dried.
●Do not use any oxidative, corrosive or reactive decontamination
solutions with this garment.
●Do not dry-clean this garment.
●Do not use hot air or a tumbling air dryer to dry this garment.
● Hang the garment in a cool, dry area to ensure proper drying of the
garment.
RETIREMENT CONSIDERATIONS
Retired garments that are not contaminated may be labeled and used “For Train-
ing Use Only.” The labeling should be done with a permanent marker.
caution
It is recommended this garment be retired from service if any of
the following criteria are met:
● Garment is abraded, cut, torn, punctured, or otherwise in
any way breached.
●Garment has received an exposure to a toxic chemical.
●Zipper has separated or imperfections are noted.