PPE Coverall Nonwoven Fabric — SMS & Spunbond for Disposable Protective Clothing

Introduction

Disposable PPE coveralls — used across healthcare, industrial, pharmaceutical, food processing and hazardous materials handling environments — are one of the largest volume applications for nonwoven fabric in the safety sector. Each year, billions of single-use coveralls are manufactured globally, with the vast majority constructed from polypropylene spunbond or SMS nonwoven fabric.

For a PPE coverall manufacturer, fabric selection is the primary cost and performance variable. The choice between plain spunbond PP, SMS laminate, SMMS, or microporous film composite determines the protection type classification, the end-user comfort, and the unit cost of the finished garment.

This guide covers the nonwoven fabric specifications for each PPE coverall type, the European Type classification system, key performance standards, and how to source PPE coverall nonwoven fabric from Pakistan.

For a complete overview of all safety related nonwoven fabrics we offer,
see: Safety Nonwoven Fabric — Full Product Range

PPE Coverall Types and Their Fabric Requirements

The European PPE Regulation (EU 2016/425) and EN standards classify disposable protective clothing into Types 1–6 based on the protection level against liquid and particulate hazards. Each type requires a different nonwoven fabric construction:

Type	Protection against	Fabric used	GSM range	Typical market
Type 1 (gas-tight)	Gas and vapour penetration	Laminated airtight composite	N/A for NW	Chemical industry, CBRN
Type 2 (non gas-tight)	Gas and vapour (limited)	Film laminate over NW	N/A for NW	Chemical handling
Type 3 (liquid-tight)	Directional liquid jets	Micorous film + NW laminate	60–80 GSM equiv.	Hazmat, pesticide
Type 4 (spray-tight)	Liquid aerosols, sprays	SMS + PE film laminate	50–70 GSM	Chemical, pharma
Type 5 (particle-tight)	Airborne solid particles	SMS / SMMS nonwoven	40–60 GSM	Asbestos, construction, pharma
Type 6 (limited spray)	Light spray, droplets	Spunbond PP or SMS	25–45 GSM	Healthcare, food, general industry

For the EN standards behind Type 5, Type 6 and anti-static requirements,
see: Medical Nonwoven Fabric Certifications — AAMI, EN 13795, ISO & OEKO-TEX Guide

Nonwoven Fabric for Type 5 & Type 6 Coveralls — The Core Market

Type 5 and Type 6 disposable coveralls represent by far the largest volume market for nonwoven fabric in the PPE sector. They are used across healthcare (isolation precautions), pharmaceutical manufacturing, food processing, construction (asbestos abatement, demolition), and general industrial environments.

Type 6 — Spunbond PP Nonwoven (Economy Coverall)

Type 6 coveralls are the most basic disposable protective garment. They provide limited splash resistance and are designed for environments where light aerosol, spray or particulate contamination is possible but not severe. Standard Type 6 coveralls are manufactured from 25–40 GSM hydrophobic spunbond PP nonwoven.

The spunbond PP fabric must meet the following minimum specifications for Type 6 coverall construction:

GSM: 25–40 GSM, depending on required garment strength and drape
Tensile strength (EN ISO 9073-3): minimum 25 N/5cm in machine direction
Tear resistance (EN ISO 9073-4): minimum 10 N in machine direction
Surface wetting (ISO 4920 — Spray Rating): minimum SR3 rating (light spray resistance)
Particle filtration (EN ISO 13934): must confirm the fabric retains its structure under light particulate load

Type 5 — SMS/SMMS Nonwoven (Enhanced Particulate Protection)

Type 5 coveralls require the fabric to provide filtration efficiency against airborne dry particles — the most commonly required property for asbestos abatement coveralls and pharmaceutical cleanroom garments. SMS and SMMS nonwoven fabric achieves this through the meltblown core layer, which acts as a depth filter against fine particles.

SMS nonwoven for Type 5 coveralls is typically specified at 40–60 GSM. The 55 GSM SMMS construction has become a standard specification for asbestos removal coveralls in the UK and European markets, satisfying EN 1073-2 (protection against radioactive contamination) and EN 13982-1 (protection against dry particles).

Key specifications for Type 5 SMS/SMMS coverall fabric:

GSM: 40–60 GSM SMS; 50–60 GSM SMMS for enhanced protection
Particle filtration efficiency (EN ISO 13934 / IEST-RP): > 70% at 0.5 micron particle size for Type 5 compliance
Seam strength: the fabric must support stitched or taped seam construction that satisfies EN 14325 seam strength requirements for coverall assembly
Anti-static treatment: specified for pharmaceutical and explosive atmosphere environments (EN 1149-5 electrostatic dissipation)

SMMS vs SMS for PPE Coveralls — Which to Specify?

Property	SMS (3-layer)	SMMS (4-layer)
Barrier performance	Good — AAMI Level 2–3 equiv.	Better — AAMI Level 3–4 equiv.
Particle filtration	Good for Type 5/6	Better for Type 5 — extra meltblown layer
Tensile strength	Standard	Higher — double spunbond outer gives added tear resistance
Softness / drape	Good	Similar — SMMS is slightly stiffer due to extra layer
Cost vs SMS	Baseline	~10–15% higher per kg
Best for	Type 6 + standard Type 5, general healthcare	Premium Type 5, asbestos, high-fluid-risk healthcare

For SMS and SMMS fabrics used in surgical barrier applications,
see: Nonwoven Fabric for Surgical Gowns & Medical Drapes — SMS & SMMS Supplier Guide

Garment Construction Requirements — What the Fabric Must Support

Beyond barrier performance, PPE coverall nonwoven fabric must be compatible with the garment assembly processes used by coverall manufacturers:

Sewn seam construction: standard spunbond and SMS fabric can be sewn on industrial sewing machines. Seam allowance of 10–15 mm is standard for coverall construction.
Taped seam construction: for Type 4 and 5 coveralls, seams are sealed with self-adhesive seam tape to eliminate particle or liquid penetration at the seam. Fabric must accept tape adhesion without delamination.
Ultrasonically welded seams: used in clean-room garment applications where stitching debris is unacceptable. SMS and spunbond PP bond well under ultrasonic welding at correct amplitude settings.
Elastic attachment: waist, wrist, ankle and hood elastics are sewn or bonded to the fabric. The fabric must maintain dimensional stability under elastic tension through the garment’s wear life.
Printing: many coveralls carry printed size markings, brand logos, or hazard category labels. Ensure the fabric surface accepts flexographic or screen printing without ink bleed.

Sourcing PPE Coverall Nonwoven Fabric from Olefins, Pakistan

Olefins Private Limited supplies SMS and spunbond PP nonwoven fabric for disposable PPE coverall and protective clothing manufacturers across GCC, Bangladesh and South Asia:

Spunbond PP: 25–50 GSM for Type 6 coveralls and economy isolation gowns
SMS nonwoven: 40–60 GSM for Type 5 & Type 6 coveralls with barrier requirements
SMMS nonwoven: 50–65 GSM for premium Type 5 and healthcare coverall applications
Hydrophobic standard finish; anti-static and three-anti treatment on request
Custom colours: white standard; blue, yellow, green or any Pantone on request for colour-coded safety garment programmes
OEM supply: production to customer specification; lot-level test reports provided.

Frequently Asked Questions — PPE Coverall Nonwoven Fabric

What fabric is used for disposable coveralls?

Disposable coveralls are most commonly made from polypropylene spunbond nonwoven (25–40 GSM for Type 6) or SMS/SMMS nonwoven (40–60 GSM for Type 5). For higher protection classes (Type 3/4), microporous film laminated over spunbond or SMS fabric is used.

What is Type 5 and Type 6 in disposable coveralls?

Type 5 provides protection against airborne dry solid particles (asbestos fibres, fine dust, pharmaceutical powder). Type 6 provides limited protection against light liquid spray and aerosol. Both types are typically made from SMS or spunbond PP nonwoven fabric. The distinction is in the particle filtration performance of the finished garment, not the fabric alone.

What GSM SMS fabric is used for PPE coveralls?

Standard Type 5/6 SMS coverall fabric is 40–55 GSM. Premium asbestos removal coveralls (SMMS construction) use 55–60 GSM. Economy Type 6 coveralls for healthcare or food industry use lighter 25–35 GSM spunbond PP without the meltblown layer.

Request PPE Coverall SMS/Spunbond Nonwoven Fabric Sample — Olefins Pakistan

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