Electrical work exposes workers to two primary hazards: arc-flash (thermal/pressure/light) and electric shock. The right Personal Protective Equipment (PPE) complements safe work practices, but never replaces establishing an Electrically Safe Work Condition (ESWC) per National Fire Protection Association (NFPA) 70E. This guide explains the major PPE types, how to choose them, and how to keep them inspection-ready.
- Arc-rated (AR) garments are Flame Resistant (FR) fabrics tested to ASTM F1959 for arc performance and labeled with an arc rating (ATPV/EBT, in cal/cm²).
- FR describes flame resistance in general; not all FR fabrics have an arc rating. For electrical tasks, AR is required.
- Arc-flash protection addresses heat/thermal energy and projectiles.
- Shock protection addresses contact with energized parts and approach boundaries. A complete PPE set often blends both.
- NFPA 70E (latest): Arc-flash risk assessment, PPE selection (incident energy or PPE Category method), approach boundaries, ESWC.
- OSHA 29 CFR 1910.132/.335: Employer duty to assess hazards and provide appropriate PPE (eye/face, head, hand, body).
- OSHA 1910.137: Design, testing, and care for electrical protective equipment (rubber gloves, sleeves, blankets, matting).
- ANSI/ASTM: ANSI Z89.1 (Class E hard hats), ANSI Z87.1 (eye/face), ASTM F1506/F1959 (AR clothing), ASTM F2178 (faceshields/hoods), ASTM D120/F496 (rubber glove specs and in-service testing), ASTM F2413 (footwear).
PPE Category | Minimum Arc Rating (cal/cm²) | Body (Arc-Rated Clothing) | Head & Face | Hands & Other | Typical Notes |
1 | ≥ 4 | AR long-sleeve shirt & pants (or coverall) | Class E hard hat; safety glasses; hearing protection | EH footwear | Entry-level AR daily wear for low incident energy tasks |
2 | ≥ 8 | AR shirt & pants (or coverall) | AR face shield with wrap-around protection + AR balaclava; Class E hard hat | EH footwear; hearing protection | Balaclava typically required with face shield at Cat 2 |
3 | ≥ 25 | Arc-flash suit (coat & pants) or layered AR system meeting rating | Arc-flash suit hood (ASTM F2178) over safety glasses | EH footwear; hearing protection | Consider remote switching/racking where available |
4 | ≥ 40 | Higher-rated arc-flash suit system | Arc-flash suit hood with appropriate rating | EH footwear; hearing protection | Highest protection level; evaluate engineering/administrative controls first |
AR = arc-rated; EH = electrical hazard. Always verify against the incident energy on the equipment label at the specified working distance.
At Category 2, most tasks require an AR balaclava worn with the face shield to protect the sides and back of the head.
Required where electrical hazards exist; inspect shell/suspension for cracks or UV damage and replace per manufacturer limits.
- Provide frontal arc protection; must be used with ANSI Z87.1 safety glasses.
- Balaclava adds side and back-of-head coverage at Cat 2.
Integrated hood/visor provides full head/neck protection; choose anti-fog, anti-scratch visors with ventilation where possible.
- Arc-rated shirts and pants or coveralls (≥4 or ≥8 cal/cm²).
- Avoid synthetic base layers that can melt/drip; use AR/FR underlayers where exposure is possible.
- Combine AR garments or use a rated suit to achieve required cal/cm².
- Ensure coverage—sleeves down, collars closed, no gaps at wrists/ankles.
- Check garment labels for ATPV/EBT and standard (ASTM F1506).
- Replace garments contaminated with flammable substances or with damaged closures.
Mandatory under face shields and hoods; choose side-shield designs for added protection.
Wear earplugs or earmuffs during switching and tasks with arc-flash potential to reduce acoustic trauma.
- Electrically Hazardous (EH) boots reduce risk of shock to ground under dry conditions.
- Dielectric overshoes may be required for certain tasks—verify per procedure.
- Limited and Restricted approach define where shock PPE and work permits are required.
- Arc-flash boundary defines where AR clothing is required based on incident energy.
- De-energize and verify absence of voltage whenever feasible.
- If energized work is justified, obtain permits and follow Approach Boundary and PPE rules.
Use insulating matting/blankets and voltage-rated tools to control shock exposure.
Select PPE with arc rating ≥ the incident energy (cal/cm²) listed on the equipment label at the specified working distance.
When permitted by NFPA 70E and equipment conditions are met, select PPE by Category 1–4 tables for the task/equipment type.
- Label shows 6.3 cal/cm² @ 18 in → Category 2 daily wear with balaclava + AR face shield.
- Label shows 28 cal/cm² → Category 3 suit with hood.
Verify size/fit, closure integrity, visor clarity, and compatibility (e.g., safety glasses under shields).
Keep test certificates and in-service dates; remove from service if punctured, cut, sticky, or past due.
Follow garment care labels to preserve AR properties; retire garments contaminated with flammables or with damaged fasteners.
Store PPE clean, dry, and out of direct sunlight/ozone; use glove bags and hood cases.
- Non-AR hoodies or synthetic base layers near the task → switch to AR/FR base layers.
- No balaclava at Cat 2 → add AR balaclava with wrap-around shield.
- Expired glove tests or missing leather protectors → implement a glove tracking log and enforce protector use.
- Out-of-date labels → refresh studies and relabel; update the PPE matrix by task.
Task | Typical System | Arc PPE (minimum) | Shock PPE | Notes |
Racking MCC bucket | 480 V | Cat 2 daily wear + AR face shield + balaclava | Class 0 gloves + protectors | Consider remote racking where available |
Infrared scan (enclosed, covers on) | ≤600 V | Safety glasses; AR daily wear if within arc boundary | N/A | Follow task table allowances |
Opening energized panel (covers off) | 480 V | Cat 2 daily wear + AR face shield + balaclava | Class 0 gloves + protectors | Verify boundaries; use insulated tools |
Switching at main switchgear | 480–600 V | Cat 3 suit with hood (site-specific) | Class 2 gloves + protectors | Review incident energy label |
(Customize to your facility’s labels, tasks, and work distances.)
- Inventory accuracy: % of required PPE available by size/type.
- Test-date compliance: on-time glove/sleeve dielectric tests.
- Training completion: don/doff and inspection training up to date.
- Field spot-checks: random audits for correct PPE use vs. label/PPE matrix.
Get an Electrical PPE Readiness Assessment
Every energized task demands the right protection—and every missed detail increases risk. Tighten your PPE program now.
References
- National Fire Protection Association. (2024). NFPA 70E: Standard for Electrical Safety in the Workplace (latest ed.). NFPA.
- Occupational Safety and Health Administration. (n.d.). Personal protective equipment, 29 CFR 1910.132; Electrical protective equipment, 29 CFR 1910.137; Selection and use of work practices, 29 CFR 1910.333. U.S. Department of Labor.
- National Fire Protection Association. (2023). NFPA 70B: Standard for Electrical Equipment Maintenance (2023 ed.). NFPA.
- ANSI/ISEA. (2014). Z89.1: Industrial Head Protection.
- ANSI/ISEA. (2020). Z87.1: Occupational and Educational Personal Eye and Face Protection Devices.
- ASTM International. (various). F1506, F1959, F2178, D120, F496, F2413.
(Abbreviations defined on first use: Electrically Safe Work Condition (ESWC), Personal Protective Equipment (PPE), arc-rated (AR), flame-resistant (FR), Motor Control Center (MCC).)