• • • SAFETY IN ENGINEERING • • •
RETHINKING ARC FLASH PROTECTION: WHY COMFORT MAY BE THE MISSING VARIABLE
BY DAVID WARD, TECHNICAL DEVELOPMENT MANAGER, ALSICO A
rc flash protection is underpinned by a framework of standards, technical guidance and risk assessments designed to safeguard those working with live electricity. However, recent research suggests these measures are not always realised in practice. In some cases, protective clothing is not worn consistently or correctly, while in others, there is uncertainty around how garments should perform or be selected.
Alsico’s latest research highlights the scale of this challenge. Fewer than half of workers in electrical environments report consistently wearing every element of their protective clothing. At the same time, many of those responsible for selecting PPE indicate they would benefit from greater clarity on newer protective measures. This points to a broader issue; arc flash protection may be less about access to PPE, and more about how it is understood, selected and used.
Comfort as a performance factor In technical environments, protective clothing is typically evaluated based on measurable criteria such as arc ratings, durability and compliance. However, these metrics rely on a critical assumption; that the garment is worn correctly and consistently.
The research suggests this assumption is not always reliable. Wearers identified comfort, fit and ease of movement as key factors influencing whether they don PPE as intended. In physically demanding environments, discomfort can quickly become a barrier to compliance.
This highlights an important point; comfort is not separate from safety performance, it directly affects it. If a garment is restrictive, heavy or difficult to manage, it is more likely to be worn incorrectly, adjusted during use, or avoided altogether. From an engineering perspective, this represents a gap between design and actual protection.
22 ELECTRICAL ENGINEERING • APRIL 2026 Understanding behaviour in
operational settings To improve PPE compliance, it is essential to understand how garments are used in practice. The research indicates that some workers adapt their PPE to suit their conditions, removing layers, combining garments with personal clothing, or substituting items entirely.
These decisions are not made lightly. Workers
are often aware of the risks associated with electrical hazards, including arc flash events. However, factors such as temperature, mobility and task efficiency can influence behaviour throughout the day. Education is also needed to ensure garments are not removed when still within hazardous proximity. PPE that performs well in controlled conditions may feel impractical during extended wear. Tasks requiring agility, climbing or repetitive movement can expose design limitations not evident at selection. This highlights the need to align PPE not only with hazard levels, but with real working conditions.
Closing the gap between specification and use
Addressing this issue requires a more integrated approach to PPE compliance, one that considers both technical performance and usability. Advances in garment design offer a clear opportunity. Modern protective fabrics can deliver required arc protection while improving breathability and reducing weight. Innovations such as alsico’s Kibo fabric, demonstrate how multi-risk garments can incorporate stretch, offering over 20 per cent flexibility, while maintaining arc flash, heat and flame protection. Stretch materials and ergonomic construction can enhance mobility, allowing wearers to carry out tasks more efficiently without compromising safety. Alongside design improvements, there is a need to
strengthen understanding across the workforce. The research suggests that both wearers and selectors can benefit from clearer guidance on how protective garments function and how they should be used. For wearers, this means accessible training that explains not only what to wear, but how garments provide protection and how misuse can reduce effectiveness. For those selecting PPE, it involves staying informed about developments in protective standards and understanding how different specifications translate into practical performance.
A further opportunity lies in integrating wearer feedback into PPE selection and development. Engineers routinely use feedback loops to refine systems and improve performance; the same principle can be applied to protective clothing. Feedback may include fit inconsistencies, thermal discomfort, or limitations in movement that only become apparent during real tasks. By listening, organisations can select or design garments that better align with operational needs.
Towards more effective protection
The challenge of PPE compliance in electrical environments cannot be addressed through regulation alone. While standards and specifications remain essential, they must be supported by solutions that reflect how work is actually carried out.
Comfort, in this context, is not a secondary consideration, it is a key enabler of consistent protection. By recognising its role, the industry can begin to close the gap between what PPE is designed to do and what it achieves in practice.
https://www.alsico.com
electricalengineeringmagazine.co.uk
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