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Author: Becky Keegan, Content Manager, ProGARM
An Arc Flash occurs when an electrical discharge travels through the air and releases an intense burst of energy. This flash is capable of causing serious harm to anyone caught by it, so adequate Arc Flash protection is of the utmost importance.
The energy expelled by an Arc Flash event can be deadly, with temperatures reaching up to 35,000ºF or more than 19,000ºC. It goes without saying; this can burn clothing and human skin within fractions of a second, even if the operative is situated five or six metres away from the Arc Flash event.
The cause of an arc flash typically stems from contact between an energized conductor, such as a bus bar or wire, and another conductor or grounded surface. This can occur due to equipment failure, uninsulated tools, or damaged cables. While it is often assumed that high voltage systems are more prone to arc flash incidents, studies have shown that low voltage systems can be equally, if not more, hazardous. Variables such as the current flow, gap size between conductors, electrode composition, and surrounding environmental factors all influence the severity of the arc flash.
It stands to reason that if equipment fails or is improperly designed or installed, an Arc Flash incident could be caused. Faulty system design can also contribute to an increased likelihood of Arc Flash incidents, also known as electrical flashovers. Damage to insulation, gaps, or wear and tear can also create the pathways needed for an unwanted electric discharge through the air. Exposed live parts or loose connections could also be the culprits. Regular inspections of your electrical systems and equipment will help to predict and prevent Arc Flash incidents.
There are other factors which can increase the likelihood of an Arc Flash incident. These causes include:
Human error is the most common cause of Arc Flash incidents. It could be a gang breaking ground and hitting a cable not marked on the services plan, a test probe touched to the wrong surface, or a tool dropped accidentally which hits a live switchgear.
Other ways that human error can cause an Arc Flash are through the improper installation of equipment, preventative maintenance that isn’t carried out properly (or at all) and failing to de-energise equipment where it’s possible. A lack of appropriate training can increase the chances of human error causing an incident. But distractions, weariness, the pressure to get the job done quickly and restore power, or just an overly-relaxed attitude can make electrical engineers bypass safety procedures, which can all too easily result in a dropped tool or making contact between energised conductors.
While PPE is essential for protecting workers from the effects of an Arc Flash, prevention should always be part of a wider safety strategy. Reducing the likelihood of an incident in the first place helps create a safer working environment for everyone involved.
Some key ways to help prevent an Arc Flash include:
Combined with the correct PPE and safety protocols, these preventative measures help reduce both the risk and severity of Arc Flash incidents.
To effectively manage Arc Flash risks in the workplace, a structured, practical approach is essential. That’s where the 4P Methodology comes in. Developed to simplify and standardise Arc Flash hazard management, this four-step process helps organisations move from assessment to action—ensuring both compliance and safety for their teams. The 4P methodology simplifies hazard assessments into four steps:
Thermal energy from an Arc Flash incident can be deadly. When someone is exposed to an Arc Flash incident, serious burns and other potentially life threatening injuries can be minimised and even avoided by effectively utilising Arc Flash garments.
An Arc Flash event may not be a daily occurrence in your business, but they are happening multiple times every working day in the UK. Risk assessment and precautions through safe working practices can be instigated by your company, and that will limit the possibility of an Arc Flash incident. These Arc Flash studies assess the risks in your working environment.
Wearing the correct Arc Flash protective garments for a specific risk level will further increase safety. There will always remain a risk, but there is significant Arc Flash protection available through wearing the correct garments.
Keeping your team safe is always top priority. And your team need to be protected against an Arc Flash incident if there is a risk of one occurring whilst they work.
If your teams work in the above industries or close to sources of high voltage, there is a good chance they need to be protected. Your first step may be to conduct an Arc Flash study at your site. An Arc Flash study is a risk assessment of a workplace environment that determines Arc Flash hazards. An expert in electrical safety conducts an assessment to ensure that a company understands the risks their workplace poses to their team and how to protect against them. Assessment providers may also offer training to increase your team’s awareness and options for periodic reviews.
How big would the bang be? That is the central question that an Arc Flash study seeks to answer. Only by knowing this can you adequately protect your team against the Arc Flash risks of their working environment. An Arc Flash study will identify areas of low risk, as well as those at high risk of an Arc Flash incident. This allows you to tailor your Arc Flash protection strategy accordingly. The study will also assess the potential severity of injury at a given distance and locate the protection boundary at which there is a severe danger of second-degree burns. There are many facets to a successful Arc Flash assessment and generally, they are adapted to fit your specific industry and requirements. They can include Arc Flash calculations, fault level studies and comprehensive site surveys.
Companies in the UK are not currently obliged to perform Arc Flash assessments on their sites. This is in stark opposition to the USA, where there is more awareness about the dangers of Arc Flash incidents. An Arc Flash study may be optional, but the positive impact on safety within your organisation is likely to be significant. Arc Flash protective clothing is vital to protect your team should they be at risk.
An Arc Flash study will highlight what level of protection is needed, allowing you to make an informed decision about your team’s Arc Flash protective clothing requirements. Arc Flash garments are available from specialist Arc Flash and non-specialist suppliers – we believe that when lives are at stake that you should trust a specialist. All garments that are rated for Arc Flash protection conform to EN Standards, but not all Arc Flash garments are created equal.
Arc Flash protection is found in specialist garments – everything from insulating warm Arc Flash base layers to Arc Flash waterproof jackets and trousers. Enhanced and effective Arc Flash protection comes through wearing layers of protective garments manufactured from inherent fibres and which feature specific Arc Flash resilient components. In addition, the level of protection or Arc Rated Category and other information about the garment’s level of protection should be clearly visible.
Not all Arc Flash protective garments are manufactured the same. Whilst many garments meet minimum standards you need to ensure that the level of protection and quality of garment are sufficient to provide the protection the wearer needs.
Quality Arc Flash protective garments from ProGARM won’t simply allow you to survive an incident, they will significantly reduce the level of injury that is sustained.
We believe when lives are at stake you should trust a specialist. Someone who is using 100% inherent fibres, that develops highly durable garments that will continue to offer a high level of protection throughout the life of the garment and that has a high level of production rigour to ensure a consistent quality and garment traceability.
Safety certification – such as EN 61482 for Arc Flash resistance – may be at the top of your list when selecting Arc Flash PPE, but test certification alone doesn’t guarantee your team’s safety. While it sets a helpful baseline, the environments and hazards employees encounter in the field are entirely different from one industry […]
If you are on the brink of choosing Arc Flash PPE, but still uncertain about the best choice for your team, there is a practical solution: wearer trials. Testing garments in real working conditions helps confirm that the selected PPE meets all safety, comfort, and functionality needs. Wearer trials allow team members—across different roles, environments, […]
For those who work in high-risk environments, every detail in their protective equipment matters. Whether it is a storm flap that keeps out rain or high-visibility strips that make you easy to spot, these thoughtful features define premium Arc Flash -rated PPE. In an industry where safety is paramount, ProGARM goes further, designing garments that […]
