Speak with an expert

Have questions about our products? Get in touch with one of our industry experts.

Contact us  

Speak with an expert

Have questions about our products? Get in touch with one of our industry experts.

Contact Us  

Speak with an expert

Have questions about our products? Get in touch with one of our industry experts.

Contact us  
Industrial Safety industries - 3 min read - 29 November 2022

Arc Flash Hazard: Are you wearing protective garments the wrong way?

The fiery split-second an arc flash explosion occurs is the moment of truth that determines if an electrical worker stays safe under their protective garments. A common assumption in many industries is that multi-norm clothing offers protection against all work environment risks. Unfortunately, that’s not always the case. Feel confident your employees have proper protection against a potentially deadly arc flash with our expert tips for wearing protective garments the right way to minimize hazards.

What is an arc flash?

An arc flash is a dangerous electrical explosion caused by a rapid discharge of energy. A short circuit connection between two conductors can generate so much heat that surrounding metal parts vaporize, then expand to form a huge pressure wall. This causes a plasma fireball up to 19,000 degrees centigrade (four times hotter than the surface of the sun) to explode directly in the electrical worker’s path. An insufficiently protected worker will almost certainly experience horrific external and internal injuries, if not death. 

Wearing the right garments, the right way

Workers injured by an arc flash are more likely to need 30 days or more for recovery due to the severity of their injuries. Protective clothing is a crucial part of arc flash protection to prevent flashovers (the transfer of fire) from causing injuries or life-threatening situations. As a Health and Safety manager, providing your employees with proper flame-resistant garments is vital, but educating them on correctly wearing them is even more crucial.

Electric utility workers

The coverall is a commonly used one-piece garment for energy distribution and electrical utility workers performing installation or maintenance work. Sometimes, a combination of a pant and a jacket is worn. Workers train thoroughly in incident simulations and are well-equipped to deal with arc flash events. Although these high-consequence events are rare, even a highly-trained employee can become complacent about safety protocols. 

Coveralls are often known for being large and cumbersome, but the benefit is that they offer complete coverage from top to bottom. Coveralls can protect workers against severe injuries in the event of an arc flash. A worker who fails to fully zip their coverall because they are feeling overheated on the work floor, for instance, can face a dangerous exposure.

Tip: Select the most comfortable clothing possible.

The coverall should be comfortable enough to wear completely closed for long periods on the workfloor or in the field. Full protection also depends on the ease of use, not just fabric comfort, so we encourage you to collaborate with garment designers to make sleeves and zippers easy to secure.

Arc flash hazardElectric utility worker ©TenCate Protective Fabrics

Non-electric utility workers

Trousers, jackets, and occasionally coveralls are the protective garments of choice in multi-standard work environments such as factories or industrial plants, thanks to their versatility. Here, electrical safety may represent just 10% of an employee’s work activities. With little training or idea of the potential risk posed by an arc flash, workers in multi-norm environments may compromise their safety by failing to properly secure their protective garments.

Most arc flashes find impact at chest height, but they can also hit a worker from below (whilst drilling in the ground) or from above (whilst repairing an overhead line). If the cuffs, waistband, and collar are not tightly closed, a tremendous burst of energy will shoot underneath the protective garments. If the worker is wearing his own cotton shirt rather than a flame-resistant undershirt underneath the jacket, this can result in very severe burns.

Tip: Provide your workers with a flame-resistant base layer.

Understanding the full spectrum of risk requires a garment system beyond the outer shell. Consider adding a flame-resistant undershirt to your protective garment system.

Determine your risks & suit up accordingly

A risk assessment and work situation analysis is the best way to lay the groundwork for the protective system you need. Once you’re aware of the risks in your work environment, you can take appropriate measures to protect your workers.

An electrical safety protocol is well and good, but make sure that the protective garments you provide your workers are comfortable enough to be used properly.

Hesitant about your protective garments?

TenCate Protective Fabrics is the expert in helping you mitigate your electrical safety risks. Do you have any questions about protective (under)garments for electrical workers or the risks related to arc flash events? Please don’t hesitate to contact us. Our advisors look forward to addressing the challenges you’re currently facing.

Contact us