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. For full SMS/SMMS barrier specifications (GSM vs AAMI Level vs Hydrostatic Head), see our single source of truth on Medical Nonwoven Fabric — Specification Table.
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 | Microporous film + nonwoven 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 (35-55 GSM std, 40-60 GSM high barrier) | 40–60 GSM | Asbestos, construction, pharma |
| Type 6 (limited spray) | Light spray, droplets | Spunbond PP or SMS (25-45 GSM) | 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. Full GSM and barrier specs: Medical Nonwoven Fabric — Master Table.
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 (aligned with our Medical pillar: 25-45 GSM for light medical).
- 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)
- Structural integrity (EN ISO 13934-1): fabric must retain its tensile 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 (1-5 micron fibre diameter), 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 and EN 13982-1. All GSM ranges aligned with our Medical Nonwoven Fabric master table (Single Source of Truth).
- GSM: 40–60 GSM SMS; 40–60 GSM SMMS for enhanced protection (Standard 35-55 GSM, High Barrier 40-60 GSM as per Medical Pillar)
- Particle filtration efficiency (EN ISO 13982-1): > 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
- Anti-static treatment: specified for pharmaceutical and explosive atmosphere environments (EN 1149-5)
SMMS vs SMS for PPE Coveralls — Which to Specify?
SMS (35-55 GSM) provides adequate barrier for Type 6 and standard Type 5 coveralls for general healthcare, food processing and light industry. SMMS (40-60 GSM) with its double meltblown layer gives higher barrier uniformity and tear resistance for premium Type 5 asbestos coveralls and high-fluid-risk healthcare at 10–15% higher cost. Full layer construction, hydrostatic head (SMS 30–50 cm vs SMMS 50–100+ cm) and AAMI mapping is detailed in our SMS vs SMMS Nonwoven Fabric: Differences & When to Use guide.
Garment Construction Requirements — What the Fabric Must Support
- Sewn seam construction: standard spunbond and SMS fabric can be sewn on industrial sewing machines. Seam allowance of 10–15 mm is standard.
- 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.
- Ultrasonically welded seams: used in clean-room garment applications where stitching debris is unacceptable.
- Elastic attachment: waist, wrist, ankle and hood elastics are sewn or bonded to the fabric. The fabric must maintain dimensional stability under elastic tension.
- Printing: many coveralls carry printed size markings, brand logos, or hazard category labels.
Sourcing PPE Coverall Nonwoven Fabric from Olefins, Pakistan
- Spunbond PP: 25–45 GSM for Type 6 coveralls and economy isolation gowns
- SMS nonwoven: 35–55 GSM standard, 40–60 GSM high barrier for Type 5 & Type 6 coveralls
- SMMS nonwoven: 40–60 GSM for premium Type 5 and healthcare coverall applications (≥50 cm H₂O for Level 3)
- Hydrophobic standard finish; anti-static and three-anti treatment on request
- Custom colours: white standard; blue, yellow, green or any Pantone on request
- OEM supply: production to customer specification; lot-level test reports provided. Full specs on Medical Nonwoven Fabric Master Table
Frequently Asked Questions — PPE Coverall Nonwoven FabricWhat fabric is used for disposable coveralls?
Disposable coveralls are most commonly made from polypropylene spunbond nonwoven (25–45 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. Full specs on Medical Nonwoven Fabric pillar page.
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.
What GSM SMS fabric is used for PPE coveralls?
Standard Type 5/6 SMS coverall fabric is 35–55 GSM standard, 40–60 GSM high barrier. Premium asbestos removal coveralls (SMMS construction) use 40-60 GSM (55 GSM standard in UK/EU). Economy Type 6 coveralls for healthcare or food industry use lighter 25-45 GSM spunbond PP. For complete GSM specifications see GSM Nonwoven Fabric Guide.
What fabric is used for disposable coveralls?
Disposable coveralls are most commonly made from polypropylene spunbond nonwoven (25–45 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. Full specs on Medical Nonwoven Fabric pillar page.
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.
What GSM SMS fabric is used for PPE coveralls?
Standard Type 5/6 SMS coverall fabric is 35–55 GSM standard, 40–60 GSM high barrier. Premium asbestos removal coveralls (SMMS construction) use 40-60 GSM (55 GSM standard in UK/EU). Economy Type 6 coveralls for healthcare or food industry use lighter 25-45 GSM spunbond PP. For complete GSM specifications see GSM Nonwoven Fabric Guide.
Request PPE Coverall SMS/Spunbond Nonwoven Fabric Sample — Olefins Pakistan
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