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WHAT IS ARC FLASH AND HOW CAN YOU PROTECT YOUR WORKFORCE?

WHAT IS ARC FLASH AND HOW CAN YOU PROTECT YOUR WORKFORCE?

6 minute read

Electrical work comes with risks. One of the most serious is arc flash.

An arc flash happens when electricity travels through the air and releases a sudden burst of energy. In a fraction of a second, it can create extreme heat, molten metal, intense light, and a powerful pressure wave.

The consequences can be severe for workers and costly for businesses.

That's why understanding the risks, selecting the right PPE, and ensuring teams are following safe working practices is essential when they’re working on or near electrical systems.

In this guide, we'll explain what arc flash is, who's most at risk, and what employers can do to help protect their workforce.

WHAT IS AN ARC FLASH?

An arc flash is an electrical discharge that passes through the air between conductors or from a conductor to earth.

It can happen for several reasons, including:

Damaged cables
Equipment failure
Loose connections
Insulation breakdown
Human error during maintenance or testing
Accidental contact with live electrical equipment

When an arc flash occurs, it releases an intense burst of energy. Temperatures can reach approximately 19,000°C, significantly hotter than the Sun's surface.

IMPORTANT: Workers do not need to touch live electrical equipment to be injured. The heat, light, pressure, and flying debris generated by an arc flash can cause serious harm from several metres away.

WHAT INJURIES CAN AN ARC FLASH CAUSE?

The effects of an arc flash can be life changing.

Arc flash incidents can result in:

Severe burns
Hearing damage
Eye and face injuries
Blast pressure injuries
Long-term physical and psychological trauma

Beyond the impact on workers, arc flash incidents can also lead to operational downtime, equipment damage, investigations, and costly project delays.

WHICH WORKERS ARE MOST AT RISK?

Arc flash hazards can affect anyone working on or near electrical systems.

Activities commonly associated with arc flash risk include:

Panel work
Live testing
Fault finding
Utility connections
Switching operations
Electrical maintenance
Groundworks near buried services
EV charging installation and maintenance

Workers in the following sectors may face a higher risk of exposure:

Rail
Utilities
Construction
Petrochemical
Power generation
Facilities management
Waste and environmental services
Logistics operations with electrical maintenance activities

TOP TIP: Managing multiple suppliers can make it harder to stay on top of safety requirements. A single source solution helps streamline ordering, improve consistency, and give teams access to PPE, workwear, and workplace safety products from one place.

SMI supports organisations across a wide range of sectors through our MY-SMI® ordering portal and nationwide supply network.

WHAT ARE YOUR RESPONSIBILITIES AS AN EMPLOYER?

Arc flash isn't just a safety concern. It's a legal responsibility.

Employers have duties under:

These regulations require employers to identify workplace hazards, assess risks, and put suitable controls in place.

If employees or contractors work on or near electrical systems, arc flash risks should form part of your risk assessment process.

The aim is not simply to provide PPE. It's to reduce risks wherever possible and ensure suitable controls are in place before work begins.

WHAT PPE IS REQUIRED FOR ARC FLASH PROTECTION?

The right PPE can help reduce the risk of serious injury if an arc flash occurs.

Depending on the task and level of exposure, this may include:

Always check that garments meet the relevant standards and are suitable for the working environment before issuing them to your team.

Not sure what protection is required? Speak to our team for guidance on selecting suitable arc-rated PPE.

UNDERSTANDING ARC FLASH STANDARDS

Arc-rated clothing must meet recognised standards that define how PPE performs against electrical arc hazards.

To stay compliant and ensure your team is protected, there are three key standards to be aware of when selecting arc flash PPE:

BS EN ISO 11611 - Protective clothing for welding. It covers risks such as molten metal, radiant heat, and flame spread.
BS EN ISO 11612 - Protective clothing against heat and flame. It protects against radiant heat, convective heat, and molten metal splashes.
IEC 61482-2 - The core standard for protective clothing against thermal arc hazards. It covers garment design, material testing, and performance requirements.

Understanding these standards is essential when selecting PPE for high-risk electrical environments.

Not all protective workwear is suitable for arc flash risks. Always check that garments are certified to the correct standard for the level of protection your team needs.

For a full breakdown of testing methods, ratings, and what each standard means in practice, read our guide: Which arc flash standards apply to you.

MANAGING ARC FLASH RISKS

Providing suitable PPE is essential, but it should never be the only control measure.

Reducing arc flash risks requires a combination of planning, procedures, training, and protective equipment.

Electrical Safety UK promotes the 4Ps framework, which provides a practical approach to managing electrical hazards and protecting workers.

PREDICT

Identify potential hazards before work begins.

This may involve electrical studies, inspections, reviewing equipment condition, and understanding where workers could be exposed to electrical risks.

PREVENT

Reduce the likelihood of an incident occurring.

This includes maintaining electrical equipment, following isolation procedures, and implementing suitable engineering controls wherever possible.

PROCESS

Put safe systems of work in place.

Clear procedures, training, permits, and communication help ensure work is carried out safely and consistently.

PROTECT

Where risks remain, provide suitable protection.

This includes arc-rated PPE, warning labels, signage, and other controls designed to help reduce the severity of injury if an incident occurs.

TOP TIP: PPE should always be viewed as one part of a wider safety strategy rather than the only control measure.

WHAT HAPPENS WHEN ARC FLASH PPE REACHES THE END OF ITS LIFE?

PPE doesn't last forever.

Over time, garments can become damaged, contaminated, or worn through regular use. Once clothing is no longer fit for purpose, it should be removed from service and replaced.

Businesses should have a clear process for:

Inspecting PPE regularly
Replacing damaged garments
Managing end-of-life PPE responsibly
Removing unsuitable clothing from use

Damaged or compromised arc-rated clothing may no longer provide the protection it was designed to deliver.

Through SMI's recycling scheme, businesses can give end-of-life workwear and PPE a more sustainable route than landfill.

DON'T FORGET CONTRACTORS

Contractors carrying out electrical work should be subject to the same safety standards as permanent employees.

That includes:

PPE standards
Risk assessments
Safe systems of work
Training requirements

Clear expectations help ensure everyone on site is working to the same level of protection.

HOW SMI CAN HELP

Managing electrical safety involves more than simply supplying PPE.

Businesses need access to suitable products, practical advice, and reliable support.

SMI supports organisations across a wide range of industries with:

Ready to get started? Speak to the team today!

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