Repairing and Replacing Vallen Zipper: Step-by-Step Tips

How to Choose the Right Vallen Zipper for Workwear and PPESelecting the right zipper for workwear and personal protective equipment (PPE) is more important than it might first appear. The zipper is not just a closure; it affects durability, safety, comfort, and compliance. For industrial garments used in construction, manufacturing, oil and gas, firefighting, or medical settings, the right zipper can extend garment life and reduce hazard risk. This article explains what to consider when choosing a Vallen zipper for workwear and PPE, compares common types, and gives practical selection and maintenance tips.

Why the zipper matters in workwear and PPE

A zipper in workwear has to withstand frequent use, abrasive conditions, contamination, and—sometimes—exposure to heat, chemicals, and sparks. Zipper failure can cause a garment to open unexpectedly, exposing the wearer to hazards or creating a safety incident. Choosing the correct zipper ensures reliable function, preserves protective properties (for flame-resistant or chemical-resistant garments), and avoids compromising compliance with standards.

Key factors to consider

• Material and construction
  • Metal zippers (brass, nickel, aluminum): High strength and abrasion resistance; often used where durability is critical. Brass is corrosion-resistant and commonly used on heavy workwear. Nickel-plated sliders offer smooth action but can corrode in harsh environments unless treated.
  • Coil zippers (nylon or polyester): Flexible, lightweight, and more snag-resistant; often used on soft shell garments and PPE that require low-profile closures. Nylon coils are common in general-purpose PPE.
  • Molded plastic zippers (polyacetal/Delrin): Good balance of strength and corrosion resistance; lighter than metal and resistant to many chemicals.
  • Vislon (large molded plastic): Durable and easy to clean; effective in corrosive or wet environments.
• Slider and puller design
  • Look for heavy-duty sliders with reinforced attachment points and ergonomic pulls for gloved use.
  • Locking sliders prevent accidental opening; non-locking may be preferred where quick release is required.
• Tape and stitching
  • Tape material (polyester, cotton blends) should match garment’s durability and washing/care needs.
  • Double-stitched or bartack reinforcement at zipper ends increases longevity under repeated stress.
• Flame and heat resistance
  • For flame-resistant (FR) garments, choose zippers whose materials don’t melt or drip at high temperature and that won’t compromise the garment’s protective rating. Metal zippers are often preferred for FR PPE; some specialty FR-rated coated coils are available.
• Chemical and corrosion resistance
  • For use around corrosive chemicals, salts, or solvents, choose corrosion-resistant materials (stainless steel, brass, coated metals, or specific plastics).
• Waterproofing and sealing
  • Water-resistant or waterproof zippers (laminated, taped, or with polyurethane coating) help maintain PPE integrity in wet environments. Sealing is important for chemical suits and outdoor gear.
• Size, tooth pitch, and strength
  • Heavier-duty applications require larger tooth sizes and higher denier tapes. Common strength classifications (e.g., #3, #5, #8, #10) indicate increasing robustness; higher numbers mean larger, stronger teeth.
• Compliance and standards
  • Ensure the zipper choice does not invalidate garment certifications (e.g., NFPA for FR clothing, EN standards for PPE). Verify manufacturer guidance and any applicable standards for closures on certified garments.
• Ease of repair and replacement
  • Consider availability of replacement sliders, stops, and full-length zippers for in-field repairs. Modular or separable zippers (two-way separating) can be practical for jackets and garments requiring full opening.
• Two-way and separating zippers
  • Two-way zippers allow opening from top or bottom—useful for mobility, sitting, or tool access. Separating zippers (down to a box-and-pin) are required for jackets and outer garments.
• Visibility and labeling
  • Reflective or high-visibility zipper tape can add to garment visibility; contrast colors can assist with quick identification and donning under low light.
• Comfort and ergonomics
  • A low-profile coil may be more comfortable under layers; consider zipper placement and guards to prevent skin abrasion or pinching.

Common zipper types for typical PPE applications

• Industrial jackets and coveralls: Metal or heavy molded plastic (#8–#10) for durability; consider two-way separating options for full-front openings.
• Flame-resistant clothing: Metal zippers (brass or stainless) or specialty FR-rated coils to avoid melting and dripping; locking sliders to prevent accidental opening.
• Chemical and hazmat suits: Taped or laminated waterproof zippers with chemical-resistant materials; often combined with storm flaps or gasketed closures.
• Outdoor/utility PPE: Vislon or molded plastic for corrosion resistance and easy cleaning; waterproof laminated coils for wet environments.
• Medical or cleanroom PPE: Small coil zippers (#3–#5) with smooth, low-profile tapes for comfort and easy laundering; stainless or coated hardware to withstand sterilization.

Choosing by environment: scenarios and recommendations

• High abrasion / heavy use (e.g., riggers, mechanics): Use metal or heavy molded plastic zippers with reinforced stitching and large tooth sizes (#8–#10).
• High heat / flame exposure (e.g., welding, firefighting): Use metal (brass/stainless) zippers or FR-rated specialty zippers; avoid nylon that melts.
• Corrosive or marine environments: Use stainless steel, brass, or high-grade plastic Vislon; avoid uncoated metals that corrode.
• Wet or chemical exposure (e.g., agricultural spraying, decontamination): Use watertight laminated zippers with chemical-resistant tape and seals.
• Frequent laundering or sterilization (medical/lab): Use stainless or coated metal sliders and nylon/polyester tapes rated for repeated wash cycles.

Practical selection checklist

• Does the zipper material resist the hazards present (heat, chemicals, saltwater)?
• Is the tooth size appropriate for expected mechanical stress (#3–#10 scale)?
• Do you need a separating or two-way zipper?
• Is the slider lock type (locking/non-locking) appropriate for task safety?
• Will the zipper maintain garment certification (FR, EN, NFPA)?
• Are replacement parts (sliders, stops, tapes) readily available?
• Is the zipper comfortable against skin and compatible with gloves?
• Is the tape and stitching compatible with the garment’s fabric and care instructions?

Installation and maintenance tips

• Use trained personnel or factory installation to ensure proper alignment and secure bar-tacks at ends.
• Reinforce zipper ends and add storm flaps for extra protection in harsh environments.
• Lubricate metal and coil zippers with appropriate zipper lubricants (dry graphite for FR contexts; silicone-free options where needed).
• Inspect zippers regularly for missing teeth, worn sliders, or separated tape; repair promptly to avoid safety incidents.
• Replace rather than patch zippers on FR garments if their integrity is compromised.

Repair and replacement guidance

• Small slider issues: try replacing the slider before changing the whole zipper; many sliders are replaceable in-field if the stops can be opened and re-crimped.
• Missing teeth or extensively damaged tape: full zipper replacement is safer and more reliable.
• Use manufacturer-specified replacement parts for garments certified to safety standards to avoid invalidating certifications.

Cost vs. performance trade-offs

• Metal zippers cost more but give high durability and heat resistance.
• Coil and molded plastic zippers are cheaper, lighter, and corrosion-resistant but may not suit high-heat or extreme-abrasion uses.
• Waterproof/laminated zippers add cost but are necessary for chemical and wet-environment PPE.

Comparison (high-level)

Quick selection examples

• Welding jacket: brass or stainless metal separating zipper, locking slider, reinforced ends.
• Offshore work jacket: Vislon or stainless zipper with corrosion-resistant slider, waterproof seam sealing.
• Lab coat / medical coverall: #3–#5 coil zipper with stainless or coated slider, easy-to-clean tape.
• Chemical splash suit: laminated waterproof zipper with gasketed closure and taped seams.

Final recommendations

Choose the zipper that matches the dominant hazard (heat, chemical, abrasion, corrosion) and user needs (glove use, mobility, frequent laundering). Prioritize materials that preserve the garment’s safety certification and ensure maintenance/repairability. When in doubt, consult Vallen product specifications and test samples in the intended environment before committing to large orders.