Arc flash PPE is specialist personal protective equipment designed to help reduce injury if an arc flash incident occurs.

An arc flash can release intense heat, light, molten metal, sound and pressure in a very short time. For electrical workers and authorised personnel, the right PPE can help reduce the severity of burns and other injuries if an incident happens.

However, arc flash PPE does not remove the hazard. It should be treated as the last line of defence, not the whole safety strategy.

The safest approach is to understand the arc flash risk first, reduce the risk where possible, apply safe working practices and then select PPE based on the assessed hazard. Covol Engineering supports this through arc flash awareness training, arc flash and fault level assessments, and arc flash mitigation services.

What does arc flash PPE protect against?

Arc flash PPE is designed to protect against the thermal effects of an electric arc.

During an arc flash incident, electrical energy can be released as extreme heat, light and explosive force. This can create several hazards, including:

• Severe burns
• Molten metal
• Intense light
• Hot gases
• Pressure waves
• Flying debris
• Sound impact
• Damage to electrical equipment

Arc flash PPE helps reduce the risk of injury from these hazards, particularly burn injury. It does not make the work safe on its own, and it does not prevent an arc flash from happening.

This is why PPE should always be used alongside proper risk assessment, safe systems of work, training and suitable control measures.

How is arc flash PPE different from standard PPE?

Standard PPE is designed to protect against general workplace hazards. This may include hard hats, gloves, eye protection, safety footwear or high-visibility clothing.

Arc flash PPE is different because it is designed specifically for electric arc thermal hazards.

That matters because not all protective clothing is suitable for arc flash risk. Flame-resistant clothing is not automatically the same as arc-rated clothing. Arc-rated PPE must be suitable for the level of arc flash hazard identified by the assessment.

For example, a normal work jacket may offer basic protection against minor workplace contact hazards, but it may not provide suitable protection against the thermal energy released during an arc flash event.

Arc flash PPE should be selected because it is suitable for the electrical hazard, not because it looks similar to other safety clothing.

When is arc flash PPE needed?

Arc flash PPE may be needed when authorised personnel are working on or near electrical equipment where an arc flash hazard has been identified.

This could include tasks such as:

• Switching operations
• Electrical inspection
• Testing and fault-finding
• Maintenance near energised equipment
• Work on switchgear
• Work near exposed live parts
• Tasks where isolation is not possible or where residual risk remains

The need for PPE depends on the task and the assessed hazard. It is not enough to say that all electrical work needs the same PPE, because different systems and tasks can create very different levels of risk.

Before PPE is selected, the organisation should understand the electrical system, the available fault current, the likely clearing time of protective devices and the potential incident energy.

That is why arc flash PPE is closely linked to an arc flash and fault level assessment.

How do you know what arc flash PPE is required?

The correct arc flash PPE should be based on an arc flash assessment, not assumption.

An assessment can help determine:

• Where arc flash hazards may exist
• The likely incident energy level
• Arc flash boundary distances
• Fault current levels
• Protective device clearing times
• Equipment-specific risk areas
• Suitable PPE recommendations
• Warning label information

Covol’s Arc Flash and Fault Level Assessment service reviews electrical systems, fault current, incident energy and arc flash boundaries to provide practical recommendations for protecting people, equipment and operations.

This information allows teams to make informed decisions about PPE rather than relying on generic rules or habit.

If the assessment shows that certain equipment has a higher arc flash risk, the PPE and working method may need to reflect that. If mitigation work reduces the incident energy, the PPE requirement may also change.

Why arc flash PPE should not be your only control

Arc flash PPE is important, but it should never be the only control.

PPE can help reduce injury severity if an arc flash occurs. It does not stop the fault from happening. It does not remove the energy in the system. It does not replace safe isolation, planning, competence or engineered risk reduction.

The HSE’s PPE guidance explains when and how PPE should be used to control risks at work, but PPE should sit within a wider risk management approach rather than being treated as the first solution.

A stronger arc flash safety approach may include:

• Avoiding live work where possible
• Safe isolation procedures
• Reviewing task planning
• Improving protection settings
• Reducing fault clearing times
• Engineering controls
• Arc flash mitigation
• Clear warning labels
• Suitable PPE
• Arc flash awareness training

Covol’s Arc Flash Mitigation service focuses on reducing arc flash risk by analysing fault current levels, incident energy and fault clearing times, then applying safety measures and engineering controls tailored to the site.

The best outcome is not simply giving workers more PPE. It is reducing the risk wherever reasonably practicable and making sure any remaining risk is properly understood.

Why training matters when using arc flash PPE

Arc flash PPE is only effective when people understand why they are wearing it, when it is required and what it can and cannot do.

Training helps workers understand:

• What arc flash is
• Why arc flash incidents happen
• What arc flash labels mean
• Why boundaries matter
• How PPE should be selected
• Why PPE does not remove the hazard
• When to stop and ask for further advice
• How safe working practices reduce risk

Covol’s Arc Flash Awareness Training page explains that training helps workers recognise arc flash hazards, understand why incidents occur and apply safe work practices consistently. It also reinforces that PPE is a last line of defence and that planning and control measures play a greater role in reducing risk.

This is especially important after an arc flash assessment. A report may identify the hazard, but training helps people understand how to act on the findings.

Common mistakes with arc flash PPE

Arc flash PPE is often misunderstood. Common mistakes include:

• Assuming standard workwear is arc flash PPE
• Wearing flame-resistant clothing that is not suitable for the assessed arc flash hazard
• Selecting PPE without an arc flash assessment
• Treating PPE as a substitute for isolation
• Ignoring arc flash warning labels
• Wearing unsuitable layers underneath arc-rated clothing
• Using damaged or poorly maintained PPE
• Failing to train workers on correct use
• Assuming one PPE level is suitable for every task
• Not reviewing PPE requirements after electrical system changes

These mistakes usually happen when PPE is treated as a standalone item rather than part of a wider electrical safety system.

Arc flash PPE should be supported by assessment, training, procedures and regular review.

Who is responsible for arc flash PPE?

Employers and duty holders are responsible for managing workplace risks, including electrical safety risks.

In practice, arc flash PPE decisions often involve several people, including:

• Duty holders
• Electrical engineers
• Health and safety teams
• Facilities managers
• Maintenance teams
• Authorised persons
• Contractors and competent workers

The organisation must make sure that risks are assessed and suitable controls are in place. Workers must also be competent, trained and aware of the procedures they need to follow.

Where arc flash risk exists, PPE decisions should be based on the electrical system and the work being carried out. Generic PPE selection can leave people under-protected or create false confidence.

Does arc flash PPE prevent an arc flash?

No. Arc flash PPE does not prevent an arc flash.

It is designed to help protect the person if an incident occurs. Prevention and risk reduction require a broader approach.

This may include:

• Keeping electrical systems well maintained
• Reducing fault levels where possible
• Improving protective device settings
• Reducing fault clearing times
• Using suitable isolation procedures
• Reviewing task necessity
• Applying safe working practices
• Training workers to understand the hazard
• Considering arc flash mitigation where required

If arc flash PPE is being used frequently, that may be a sign that the wider risk management approach should be reviewed. PPE has a place, but it should not become a routine substitute for safer working methods.

When should arc flash PPE requirements be reviewed?

Arc flash PPE requirements should be reviewed when the electrical system or working conditions change.

This may include:

• New switchgear installation
• Changes to protection settings
• Transformer upgrades
• Generator changes
• Network modifications
• New loads added to the system
• Changes in working practices
• Updated arc flash assessments
• Equipment replacement
• Incident or near-miss investigations

Arc flash risk is not fixed forever. If the electrical system changes, the fault current, clearing time and incident energy may also change.

A PPE recommendation that was suitable several years ago may not reflect the current system.

Speak to Covol Engineering about arc flash safety

If you are unsure what arc flash PPE your team needs, the starting point should be a clear understanding of the risk.

Covol Engineering can help you assess arc flash hazards, understand fault levels, review incident energy and identify practical ways to improve electrical safety. We can also provide tailored arc flash awareness training to help your people understand PPE, boundaries, labels and safe working practices.

Whether you need an arc flash and fault level assessment, arc flash mitigation support or training for your team, Covol can help you take a practical step towards safer electrical work. Contact the team at Covol Engineering today to learn more.