Overalls, Coveralls & Boiler Suits: A NZ Buying Guide
In NZ, “overalls”, “coveralls” and “boiler suits” are often used for the same thing: a one-piece garment that protects your clothes and body at work. The real differences are in the style (zip-front, bib-and-brace or action back), the fabric and the level of protection. Choose by your job, your hazards and your fit.
Overalls, Coveralls and Boiler Suits: What’s the Difference?
The names overlap, and suppliers use them differently. Here’s how they’re generally used:
- Overalls is the everyday NZ term for reusable one-piece workwear, including zip-front overalls and bib-and-brace styles.
- A boiler suit is the traditional name for a full-length one-piece suit with sleeves, usually in polyester-cotton or cotton.
- Coveralls often means protective suits, including disposable coveralls for dusty, dirty or contaminated work. We list these under PPE.
- Flame-resistant (FR) and arc overalls are specialised garments for welding, electrical and similar hazards.
| Style | Best for | Example in our range |
|---|---|---|
| Zip-front overalls | Workshops, farms and general trades | Bison Overall Polycotton Zip 430012 and Cotton Zip 430023 |
| Action back and bib-and-brace | Freedom of movement and durable knees | Bisley Action Back Overall BAB0007 and Painters Contrast Bib & Brace Overall BAB0422 |
| Boiler suit (stud front) | Light industrial and maintenance work | Portwest Euro Work Boilersuit S999 |
| Disposable coveralls | Dust, particles and light liquid splashes | Pro Choice Barriertech SMS Coveralls DOSMS and Esko Titan 380 BWF Coverall T380 |
| Flame-resistant overalls | Welding, electrical, and flame or arc hazards | Portwest Flame Resistant Overall D/N 6.3 CAL MF922 |
| Hi-vis overalls | Roadside and low-light work | Bisley Taped Hi Vis Action Back Overall BAB0359T |
Zip-Front Overalls
A zip front is quick to get into and a good all-rounder. The Bison range uses a YKK rust-proof metal zip, a flap pocket, a pen and phone pocket, and a tool pocket on the leg, and the fabric is UPF 50+ under AS/NZS 4399. Choose the polycotton version (260gsm, 65/35 blend) for a lighter suit, or the 100% cotton version (300gsm) for extra toughness and breathability.
Image file: 13162.jpg (existing photo on the Bison Overall Polycotton Zip 430012 product page) | Alt text: “Navy blue Bison polycotton zip-front overalls with long sleeves and chest pockets”
Action Back and Bib-and-Brace Overalls
The Bisley Action Back Overall BAB0007 uses 310gsm preshrunk cotton drill, with elasticated shoulder straps, a press-stud front, double-layer knees and an antimicrobial treatment. The Bisley Painters Contrast Bib & Brace Overall BAB0422 is made from stretch cotton canvas with abrasion-resistant contrast panels and a gusset crotch panel, so it’s built for movement.
Boiler Suits
The Portwest Euro Work Boilersuit S999 is a polyester-cotton suit (65/35, 210g) with a concealed stud front, an elasticated back waist and six pockets. The fabric is UPF 50+. The listing describes the fit as unisex and notes that ladies may need to size down, so check the size guide before you order.
Disposable Coveralls
Disposable coveralls are single-use suits for dusty, dirty or contaminated work. Check the type and rating against your hazard assessment:
- Type 5 coveralls protect against airborne particles, and Type 6 protect against light liquid splashes. The Esko Titan 380 BWF Coverall Type 5/6 is rated for both and uses a breathable waterproof fabric.
- The Pro Choice Barriertech SMS Coveralls are light and breathable, with a hood designed to fit when you’re wearing a respirator and goggles, plus anti-static properties to EN 1149.
Disposable coveralls are protective equipment, not general workwear. Match them to the hazard, and wear them with the right respirator, gloves and eye protection. Asbestos work has strict legal requirements, so follow WorkSafe’s rules and your licensed contractor’s procedures.
Flame-Resistant and Hi-Vis Overalls
If you weld or work near flame or electrical arc hazards, you need flame-resistant clothing matched to your hazard. The Portwest Flame Resistant Overall D/N 6.3 CAL MF922 is 100% cotton drill with flame-resistant reflective tape, and it’s tested to last a minimum of 60 washes. For roadside and low-light work, the Bisley Taped Hi Vis Action Back Overall BAB0359T adds reflective tape to the action back design. See our guide to hi-vis compliance for the standards.
How to Choose: Five Questions
- What are the hazards? Dirt and oil, paint, dust, chemicals, heat, flame and traffic each point to a different type of suit.
- What fabric suits the job? Cotton drill is tough and breathable, polycotton is lighter, stretch canvas moves with you, and FR cotton is for flame hazards.
- How heavy is the fabric? Fabric weight is measured in grams per square metre (gsm). Heavier fabric is generally tougher and warmer, while lighter fabric is cooler. The examples above range from 210gsm to 310gsm.
- How will you get in and out? Zip fronts are quick, and press studs and concealed studs are secure.
- What extras do you need? Think about knee protection, tool and phone pockets, reflective tape, and UPF 50+ sun protection.
Sizing and Fit
A good overall fits through the shoulders and torso without pulling, with enough length in the body to bend, squat and reach. Check the size chart before you order, because sizing differs by brand. Bison overalls are sized from 72 to 122, and Bisley uses regular, short and long fittings (for example 77 to 117R, 92 to 132S and 74 to 94L). Allow for the layers you’ll wear underneath. If you’re buying unisex overalls in smaller sizes, see our women’s workwear guide.
Care Tips
Wash overalls to the label. Flame-resistant garments need to be washed as directed to keep their protection, and the MF922 is tested to last a minimum of 60 washes in a normal cycle. Replace overalls that are torn, soaked in oil or flammable substances, or have faded hi-vis or damaged reflective tape.
Frequently Asked Questions
What’s the difference between overalls, coveralls and boiler suits?
In NZ, the three terms overlap. Overalls is the everyday term for reusable one-piece workwear, a boiler suit is a traditional full-length suit with sleeves, and coveralls often means protective or disposable suits. Check the product description for the exact style and protection.
What are bib-and-brace overalls?
Bib-and-brace overalls are sleeveless overalls with a chest bib and shoulder straps. They suit jobs where you need freedom of movement in your arms, like painting, and they’re easy to wear over a shirt or jumper.
What are the best overalls for mechanics and workshops?
Choose durable cotton or polycotton overalls with a strong zip, tool pockets and room to move. Zip-front overalls such as the Bison range suit workshops. If there’s a flame or arc risk, choose flame-resistant overalls instead.
Do I need flame-resistant overalls for welding?
Welding and electrical work usually call for flame-resistant clothing matched to the hazard. Your employer’s risk assessment should specify what you need. Standard cotton or polycotton overalls aren’t designed to protect against flame or arc hazards.
What are disposable coveralls used for?
Disposable coveralls protect your clothes and skin from dust, particles and light liquid splashes. They’re used in painting, insulation, cleaning and other dirty or contaminated work. Check the type rating against your hazard, and wear the right respirator and gloves with them.
What does gsm mean on overalls?
GSM is grams per square metre, a measure of fabric weight. Heavier fabric, such as 300gsm cotton, is generally tougher and warmer. Lighter fabric, such as 210gsm polycotton, is cooler and more flexible, so it suits warm conditions or lighter duties.
How should overalls fit?
Overalls should sit comfortably through the shoulders and torso without pulling when you bend, squat or reach. The legs shouldn’t drag on the ground or catch on your boots. Allow for the layers you’ll wear underneath, and check the brand’s size chart.
Ready to choose? Browse our overalls, flame-resistant overalls and coveralls. Need them with your company logo? Enquire about branded workwear.