How to Choose the Right PPE for Chemical Handling: A Step-by-Step Risk-Based Guide

Picking the right PPE for chemical work starts with understanding what’s really happening in your workplace. We’ll walk through how to identify hazards, assess the level of risk, and choose protection that genuinely keeps people safe. Taking a risk-based approach supports compliance and helps create a safer, more confident working environment.

Why PPE matters in chemical handling

Working with chemicals exposes people to all sorts of hazards, from mild skin irritation to serious burns, breathing issues, or long-term health effects. Using the wrong PPE can make those risks far worse.

Engineering controls and good procedures should always be your first line of defence, but PPE is essential when exposure can’t be fully removed. Under UK COSHH rules, employers must provide suitable protective gear whenever hazardous substances are used.

When is PPE required?

PPE is needed whenever employees work with corrosive liquids, solvents, reactive materials, or any substance that might splash, spill, or become airborne. This often includes tasks like decanting, transferring chemicals between containers, or cleaning up contamination. The level of PPE depends on two things: how severe the risk is and how likely exposure could occur.

1) Identify and Assess the Risks

Understand the chemicals involved

Start by collecting information about the chemicals in use. Safety Data Sheets (SDS) will tell you how hazardous a substance is, how it behaves, and what it reacts with. Whether a chemical is corrosive, volatile, oxidising, or simply irritating will guide the type of protection needed.

Look at real exposure scenarios

Next, think about how workers actually use the substance. Could they be exposed through splashes, immersion, vapours, or spills? Look at normal working conditions as well as worst-case situations. How often and how long someone is exposed also affects which PPE is appropriate.

2) Match the Right PPE to the Chemical Hazards

Chemical-resistant clothing

Aprons, coveralls, and full-body suits all offer different levels of protection. The key is choosing the right material for the specific chemicals you’re using. Some fabrics resist permeation or degradation better than others – PVC, Tychem, and nitrile each have strengths depending on the substance.

Gloves and hand protection

Hands are the most exposed during chemical work, so glove selection is critical. Look at the glove’s breakthrough time, thickness, dexterity, and material. Nitrile, neoprene, and butyl rubber each behave differently depending on the chemical. Gloves should also be checked and replaced regularly.

Eye and face protection

Goggles offer protection against splashes, while face shields give extra coverage for larger volumes or higher-risk tasks. For chemicals that give off vapours, vapour-resistant models may be necessary.

Respiratory protection

If vapours or aerosols are a concern, a respirator might be required. The filter type has to match the chemical—for example, A-type filters are used for organic vapours. Fit testing is essential to ensure a proper seal.

3) Think About Fit, Comfort, and Practical Use

Get the fit right

PPE only works if it fits properly. Clothing should cover the body without restricting movement, and respirators must seal correctly to the wearer’s face.

Prioritise comfort and usability

If PPE is uncomfortable—too hot, too rigid, or difficult to move in—workers are less likely to wear it properly. Choosing options that balance protection with comfort encourages consistent use.

Make sure equipment works together

Workers often wear multiple layers of PPE. Gloves, suits, boots, and respirators should all be compatible so they don’t interfere with each other or leave gaps in protection.

4) Train, Monitor, and Review

Train workers thoroughly

Proper donning and doffing techniques reduce the chance of contamination. Workers also need to know how to store, clean, and look after their PPE.

Monitor condition and performance

Regular checks help spot wear and tear, chemical damage, or other issues early. Tracking incidents or near misses can highlight whether PPE is performing as expected.

Review and update PPE regularly

Risk assessments aren’t a one-off. Whenever chemicals, processes, or regulations change, PPE requirements should be updated too.

Conclusion

Choosing the right PPE for chemical handling takes research and ongoing attention. A structured, risk-based approach ensures workers get the protection they need for the chemicals and situations they’re dealing with. By understanding the hazards, selecting appropriate materials, ensuring good fit and comfort, and regularly reviewing what’s in place, organisations can maintain strong safety standards.

For dependable chemical splash protection, you can explore Hazchem Safety’s specialist PPE range: https://www.hazchemsafety.com/ppe/chemical-splash/