Every refrigerant used in HVAC systems poses specific health and safety risks during handling. Frostbite from liquid contact, asphyxiation from vapor displacement of oxygen, and flammability with A2L compounds are all real hazards that proper personal protective equipment is designed to mitigate.
Despite these risks, PPE compliance in the field is inconsistent. Solo technicians on tight schedules often skip eye protection or reach for whatever gloves are handy. This guide provides a practical framework for what you should be wearing and why, organized by refrigerant category and service scenario.
Baseline PPE: Required for All Refrigerant Work
Regardless of refrigerant type, every service event involving refrigerant handling requires this minimum PPE:
Safety Glasses or Chemical Splash Goggles
A splash of liquid refrigerant to unprotected eyes can cause cryogenic burns and permanent eye damage in seconds. Safety glasses with side shields work for most scenarios. When working under high-pressure fittings where a liquid spray could contact your face directly, upgrade to chemical splash goggles that seal against your face.
Insulated Gloves Rated for Cold Contact
Standard leather or nitrile gloves do not protect against cryogenic contact. Use insulated cryogenic-rated gloves with a waterproof outer layer and insulating mid-layer. They should be long enough to cover your wrists and lower forearms, where splashes commonly occur during hose connections.
Closed-Toe, Non-Slip Footwear
Closed-toe shoes or boots prevent liquid refrigerant from contacting your feet. Non-slip soles are equally important in wet mechanical rooms and on rooftops. Steel-toe boots provide additional protection when handling heavy cylinders.
Additional PPE by Refrigerant Category
ODS Refrigerants (R-22, R-11, R-123)
ODS refrigerants are classified A1 (non-flammable), so flammability PPE is not required. However, R-123 has a low Occupational Exposure Limit of 50 ppm. When servicing R-123 in enclosed mechanical rooms, continuous air monitoring and respiratory protection may be necessary. For R-22, the primary confined-space risk is oxygen displacement rather than direct toxicity.
HFC Refrigerants (R-410A, R-134a, R-404A)
HFC refrigerants are also A1 (non-flammable) with relatively high exposure limits. The baseline PPE is sufficient for standard work. The primary hazards are cryogenic exposure from liquid contact and asphyxiation in confined spaces. HFC vapors are heavier than air and displace oxygen at floor level. If you feel lightheaded or have difficulty breathing in an enclosed space, leave immediately.
A2L Refrigerants (R-454B, R-32, R-452B)
A2L refrigerants add flammability hazards requiring additional PPE:
- Anti-static clothing: Synthetic fabrics generate static electricity that can serve as an ignition source. Wear cotton or anti-static garments. Avoid removing clothing in the work area.
- Anti-static footwear: ESD-rated shoes or boot straps dissipate static charge, especially important on carpeted or synthetic flooring.
- No metallic accessories: Rings, watches, and jewelry can create sparks on contact with electrical terminals. Remove them before working on A2L systems.
Natural Refrigerants (R-290, R-744, R-717)
- R-290 (propane): Classified A3 (highly flammable), requiring flame-resistant clothing and full anti-static measures.
- R-717 (ammonia): Classified B2L (toxic and mildly flammable), requiring full respiratory protection and chemical-resistant clothing.
- R-744 (CO2): Operates at extremely high pressures (1500+ psi in transcritical systems), requiring heavy-duty gloves, face shields, and asphyxiation awareness.
Confined Space PPE Upgrades
Equipment closets, crawl spaces, attics, and below-grade utility rooms may require PPE beyond the baseline.
Upgrade when:
- The work area has limited ventilation that cannot be improved with portable fans
- The system charge is large relative to room volume
- You are working below grade where refrigerant vapors accumulate
- The service involves opening the system in an enclosed space
What to add:
- Portable oxygen monitor: A personal O2 monitor alerts you if levels drop below 19.5%. This is inexpensive insurance against asphyxiation.
- Refrigerant concentration monitor: For A2L work, a monitor that alarms when concentrations approach the LFL adds a critical safety layer.
- Respiratory protection: A half-face respirator with organic vapor cartridges works for brief exposures. For IDLH concentrations, only SCBA or supplied-air respirators are adequate.
PPE Inspection and Maintenance
Build these checks into your routine:
- Gloves: Inspect for cracks and tears before each use. Cryogenic gloves lose insulating properties over time, even without visible damage.
- Safety glasses/goggles: Clean lenses regularly and replace scratched ones. Verify goggles still seal properly.
- Monitors: Calibrate oxygen and refrigerant monitors on the manufacturer’s schedule. An inaccurate monitor creates false confidence.
Documenting PPE in Your Compliance Logs
While EPA regulations focus on refrigerant handling rather than PPE specifically, OSHA general duty clause requirements call for documenting safety measures. Recording PPE use strengthens your compliance record and demonstrates professional diligence.
FieldPad’s compliance log includes the A2L safety checklist, which covers PPE verification as one of the six mandatory items. For all service events, you can add notes documenting safety measures taken, creating a searchable history of your safety compliance.
Key Takeaways
- Minimum PPE for all refrigerant work includes safety glasses or goggles, insulated cryogenic-rated gloves, and closed-toe footwear.
- A2L refrigerants add flammability PPE requirements: anti-static clothing, anti-static footwear, and removal of metallic accessories.
- Confined spaces require upgraded protection, including portable oxygen monitors and potentially respiratory protection.
- Inspect your PPE regularly. Damaged gloves and uncalibrated monitors provide a false sense of security.
- Document your PPE compliance as part of your service records. FieldPad’s A2L safety checklist captures PPE verification automatically for flammable refrigerant service events.
- Never compromise on eye protection. Cryogenic burns to unprotected eyes happen instantly and can cause permanent damage.
Sources & Regulatory References
- OSHA Personal Protective Equipment Standards — OSHA requirements for workplace PPE
- ASHRAE Standard 34 — Refrigerant safety and toxicity classifications
- OSHA Confined Spaces — OSHA standards for confined space entry and atmospheric monitoring
