Five Common Mistakes in Wearing Arc Flash Clothing

— Small Errors That Can Lead to Major Consequences**

Arc flash incidents are extremely destructive, with temperatures exceeding 19,000°C, pressure waves strong enough to knock workers off their feet, and vaporized metal capable of penetrating skin instantly. In such high-risk environments, even if a worker is wearing arc-rated clothing, incorrect wearing practices can severely reduce protection or even render the protection ineffective.

Below are the five most common mistakes observed in the power, energy storage, photovoltaic, and industrial maintenance sectors, along with their consequences and best practices.

Mistake 1: Leaving zippers or closures partially open

Incident analyses show that over one-third of upper-body burn injuries occur because closures were not fully secured, such as:

• A partially open collar

• A zipper not pulled to the top

• Buttons left unfastened

• Loose cuffs

These small gaps become “heat entry points,” allowing hot gases to reach the skin during an arc flash.

Consequences:

• Localized deep burns

• High-temperature gases rushing into the chest and neck

• Injuries far exceeding the size of the opening

• Second- and third-degree burns

Correct practice:

All zippers, buttons, and Velcro closures must be fully secured with no gaps at the collar or front opening.

Mistake 2: Wearing synthetic fabrics under the arc flash clothing

Many workers wear quick-dry shirts, athletic wear, polyester undergarments, or printed T-shirts under their arc flash suits.
This is extremely dangerous.

Arc flash temperatures cause synthetic fibers to melt instantly and bond to the skin, creating severe, hard-to-treat injuries.

Consequences:

• Molten material embedding into the skin, requiring surgical removal

• Deep burns with high infection risk

• Long recovery times lasting months or even a year

• More severe than skin exposed without clothing

Correct practice:

The base layer must be 100% cotton or arc-rated, with no synthetic components.

Mistake 3: Wearing an incorrect size (too tight or too loose)

Too loose:
Creates a “chimney effect,” allowing hot gases to flow into the clothing and cause internal burns.

Too tight:
Reduces the air insulation layer, increases heat transfer, and restricts movement during emergency response.

Consequences:

• Internal burns more serious than external burns

• Restricted mobility during accidents

• Reduced protective performance by 20–40%

Correct practice:

Ensure the suit fits properly—allowing a suitable air gap for insulation without being baggy.

Mistake 4: Missing matching arc-rated PPE components

Some workers only wear arc flash clothing but neglect head, hand, face, or foot protection, such as:

• Using a regular hard hat instead of an arc-rated helmet/hood

• Wearing general-purpose gloves instead of arc-rated or insulated gloves

• Wearing normal sports shoes

• Using non–arc-rated face shields or no shield at all

These weak points often become the first to sustain injury.

Consequences:

• Facial and eye injuries from intense light and heat

• Severe hand burns affecting long-term function

• Foot injuries caused by molten metal penetration

• Metal accessories (watch, belt, zippers) heating instantly and acting as “localized branding irons”

Correct practice:

Use a complete arc flash PPE system: suit, gloves, face shield, helmet, and footwear—none can be omitted.

Mistake 5: Selecting an arc rating lower than the job’s energy level

Many power, PV, and energy storage workers cannot accurately evaluate the incident energy level, leading to the selection of insufficient PPE.
When the job’s energy exceeds the clothing’s ATPV/EBT rating, the suit cannot stop the heat.

Consequences:

• Thermal energy breaks through the clothing

• Protection fails instantly

• Serious burns even when wearing arc-rated clothing

Correct practice:

Ensure:
PPE Arc Rating ≥ Incident Energy (cal/cm²)

For example:

• 4 cal/cm² → ARC 1 minimum

• 8 cal/cm² → ARC 2 minimum

• 25 cal/cm² → ARC 3/ARC 4 required

Conclusion: Wearing it wrong can be more dangerous than not wearing it

Arc flash clothing is not simply “put it on and go”—it is a complete, precise, and highly engineered protective system.
Even small deviations in how it is worn can reduce protection by 50% or cause total failure.

Every button, every zipper, every layer matters.
Correct wearing is the most basic—and most critical—form of self-protection.

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