Personal Protective Equipment (PPE) should make electrical work safer, not harder. Many incidents begin with small, preventable errors. Here we explain the most common mistakes, why they matter, and how to fix them quickly.
PPE supports safe work, but it does not replace creating an Electrically Safe Work Condition (ESWC) whenever feasible.
Electrical work involves two hazards. Arc-flash protection reduces burn and blast injury. Shock protection reduces current through the body. Crews often need both at the same time.
Arc-rated (AR) garments are flame-resistant fabrics tested for arc performance and labeled with an arc rating in cal/cm². For electrical tasks, AR clothing is required. General FR alone is not enough unless it is also arc-rated.
Non-AR outerwear or synthetics near the hazard
Why it matters. Common synthetics can melt or drip in an arc event, which makes burns worse.
Fix it. Require AR shirts and pants for tasks within the arc-flash boundary. Keep outer layers AR. Do not allow non-AR hoodies near energized work.
Quick check. Shirt and pants labels show an arc rating and ASTM F1506 compliance.
Missing the balaclava at Category 2
Why it matters. A face shield alone does not protect the sides and back of the head at Category 2 tasks.
Fix it. Use an AR face shield with wrap-around protection and an AR balaclava at Category 2. For higher energies, use a full arc-flash hood.
Quick check. The PPE matrix says Cat 2. The kit includes a balaclava and shield.
Face shield used without safety glasses
Why it matters. Debris and pressure can bypass a shield from below or the side.
Fix it. Wear ANSI Z87.1 safety glasses under shields and hoods. Keep anti-fog wipes handy.
Quick check. Every kit includes safety glasses, not just a shield.
Wrong glove class or missing leather protectors
Why it matters. Shock protection depends on the correct voltage-rated rubber gloves. Leather protectors prevent cuts and punctures.
Fix it. Match glove class to maximum nominal voltage. Wear leather protectors over rubber gloves unless there is a documented exception.
Quick check. Class 00 to 4 labels are visible. Protectors are present and sized correctly.
Expired glove tests or poor storage
Why it matters. Rubber ages and can crack. Out-of-date gloves are a hidden risk.
Fix it. Air test and inspect before each use. Keep dielectric test dates current, typically every six months or per manufacturer. Store in glove bags, cuffs down, away from heat and ozone.
Quick check. Each pair has a clear in-service and test date. Storage is clean and dry.
Arc-rated hood with no hearing protection
Why it matters. Arc events and switching can be loud enough to damage hearing.
Fix it. Add earplugs or earmuffs for switching and arc-flash tasks. Many hoods accept low-profile hearing protection.
Quick check. Hearing protection appears in the task PPE matrix.
Using the wrong hard hat class in electrical areas
Why it matters. Class G or C helmets are not designed for electrical exposure.
Fix it. Use ANSI Z89.1 Class E hard hats in electrical areas. Inspect shells and suspensions and replace per manufacturer guidance.
Quick check. Helmet is marked Class E and in good condition.
Treating EH footwear as full shock protection
Why it matters. Electrically hazardous (EH) boots reduce shock to ground under dry conditions, but do not replace rubber gloves, sleeves, insulating mats, or safe approach distances.
Fix it. Treat EH footwear as one part of a full shock protection plan. Use insulating tools and mats where required.
Quick check. Crews never rely on boots alone. Gloves, sleeves, and mats are used when needed.
Poor fit, open collars, and coverage gaps
Why it matters. Gaps at the neck, wrists, or ankles expose skin to heat and debris.
Fix it. Close collars, keep sleeves down, and use garments that fit. Replace damaged closures.
Quick check. No exposed skin within the arc-flash boundary. Garments fit the person wearing them.
Laundering AR garments the wrong way
Why it matters. Some detergents reduce arc performance. Contamination can make garments ignite.
Fix it. Follow care labels. Avoid bleach and softeners unless allowed by the manufacturer. Retire garments that are contaminated with flammables or are damaged.
Quick check. Laundry instructions are posted and followed. Compromised gear is removed from service.
PPE that does not match the label or the task
Why it matters. Over- or under-protection increases risk, heat stress, or both.
Fix it. Choose PPE by the incident energy on the equipment label, or by the NFPA 70E PPE Category tables when conditions allow. Combine arc-flash and shock PPE as needed.
Quick check. Crews can point to the label and explain the PPE choice.
Out-of-date labels and one-lines
Why it matters. Old studies and labels lead to wrong PPE choices. One-line diagrams that are not current confuse isolation and Lockout or Tagout (LOTO).
Fix it. Re-run short-circuit, coordination, and arc-flash studies when settings or topology change. Relabel equipment and update the one-line. Place current drawings where crews can reach them, for example QR-linked PDFs at point of use.
Quick check. Labels match equipment condition. The one-line is current and easy to find.
No program owner, no records, no training
Why it matters. Without ownership, small lapses become patterns. Audits will find the gaps.
Fix it. Assign a PPE program owner. Keep inventory, test logs, and training records. Use field spot checks and refreshers.
Quick check. There is a current list of who owns the program, where gear is stored, and when items were last inspected or tested.
Common mistake | Immediate fix | Longer term control |
Non-AR outerwear | Replace with AR daily wear | Standardize AR uniforms for exposed tasks |
No balaclava at Cat 2 | Add AR balaclava with shield | Update the PPE matrix and train crews |
Wrong glove class | Reissue correct class and protectors | Post a glove-class chart at point of use |
Expired glove tests | Pull from service and test | Set a 6-month test cadence with reminders |
Class G hard hats in electrical areas | Swap to Class E | Add Class E to standard issue list |
Relying on EH boots | Add gloves, sleeves, mats | Update task procedures and training |
Open collars or poor fit | Correct coverage and fit | Size sets by worker and replace worn gear |
Wrong PPE vs. label | Recheck label and task | Refresh arc-flash study and relabel as needed |
Out-of-date one-lines | Post current drawings | Add QR-linked PDFs at switchgear |
Use the incident energy value on the equipment label at the stated working distance. Select PPE with an arc rating equal to or greater than that value.
If conditions match the NFPA 70E tables, select PPE by Category 1 to 4 for the task and equipment type. At Category 2, include a balaclava with a wrap-around face shield. At higher categories, use a full hood.
Match arc-flash clothing to incident energy and match shock PPE to voltage. This often means AR daily wear with face protection plus rubber gloves with leather protectors and sleeves.
- Label shows 6.3 cal/cm² at 18 inches. Use Category 2 daily wear with an AR face shield and balaclava, Class 0 gloves with protectors if shock is present.
- Label shows 28 cal/cm². Use a Category 3 suit with hood and the correct glove class for the voltage.
Inspect PPE before use. Verify clear visors, intact closures, and correct size. Close collars and keep sleeves down.
Air test and inspect before each use. Maintain dielectric re-test dates, typically every six months or per the manufacturer. Keep certificates on file.
Follow care labels to preserve AR properties. Remove contaminated or damaged garments from service.
Store PPE clean and dry, away from sunlight and ozone. Use glove bags and hood cases.
Record circuit moves, new equipment, and capacity notes on the one-line and labels so crews select PPE correctly.
Post simple charts where work happens. Include glove class, face protection, and clothing level by task.
Provide training at onboarding and refreshers. Use spot checks to reinforce correct PPE use.
Get an Electrical PPE Readiness Assessment
Small PPE gaps create big risks. Close them before they become injuries or outages.
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.
- ASTM International. (various). F1506, F1959, F2178, D120, F496, F2413.
- ANSI/ISEA. (2014, 2020). Z89.1 Industrial Head Protection; Z87.1 Eye and Face Protection.