PPE W


hen people think about arc flash protection, the conversation almost always starts with the coverall. For years, employers have focused on selecting the correct arc flash rating, investing in increasingly advanced protective clothing and ensuring garments comply with the latest standards. Arc flash is one of the most dangerous yet often misunderstood hazards in electrical environments. With temperatures hotter than the surface of the sun and risks including severe burns, blindness and fatalities, understanding and mitigating arc flash risk is critical for businesses operating with or around high or low-voltage systems.


So, whilst conversations around arch flash PPE remain crucial, they overlook one critical question: what is being worn underneath?


RETHINKING THE ARC FLASH CLOTHING SYSTEM Arc flash PPE has never been about a single garment. It is a complete protective system, where every layer contributes to the level of protection a worker receives. Yet, while organisations invest considerable time selecting the right outerwear, there is often far less understanding of the role flame- resistant base layers play in reducing injury. As electrical infrastructure becomes more advanced and protective clothing continues to evolve, it is time to broaden our perspective. Protection does not stop at the outer layer. Alsico UK’s research into protective uniforms revealed a concerning gap between PPE provision and PPE use, with the statistics showing that only 40


WHY COMFORT IS BECOMING CRITICAL


per cent of those working with live electricity always wear every part of their provided uniform. Even more concerning, 19 per cent said they do so despite being aware of the potential dangers.


The implication is clear: the challenge is not always the availability of suitable PPE, it is ensuring workers understand how the entire clothing system is designed to function and the risks involved in not wearing it.


THE OVERLOOKED LAYER


One of the biggest education gaps across the industry concerns, flame-resistant underlayers. Many workers understand the importance of wearing an arc-rated coverall but give far less thought to the clothing underneath.


Flame-resistant base layers provide an additional protective barrier that can help reduce heat transfer during an incident, while also protecting areas that may become exposed if an outer garment shifts or is opened during work.


By contrast, everyday clothing made from synthetic materials such as polyester or nylon presents a significant hazard. Under the extreme temperatures generated during an arc flash, which can reach almost 20,000°C, these fabrics can melt onto the skin, significantly increasing the severity of burn injuries. It’s a risk that remains widely underestimated because workers naturally focus on the garment they can see rather than the one hidden beneath it.


HEAT IS CHANGING THE COMPLIANCE CHALLENGE The education gap becomes even more significant


18 SUMMER/AUTUMN 2026 | INDUSTRIAL COMPLIANCE


By David Ward, technical development manager, Alsico during the summer months.


UK summers are becoming warmer and lasting longer, placing increasing pressure on workers operating in physically demanding environments. Wearing multiple protective layers while carrying out electrical work can quickly become uncomfortable, particularly during long shifts or when working outdoors.


During warmer weather, workers may change the way they wear their PPE, with coveralls left partially unzipped, sleeves rolled up, collars opened and flame-resistant base layers swapped for lighter everyday clothing or removed altogether. This represents an important shift in how employers should think about PPE compliance. If PPE is uncomfortable enough that workers feel compelled to modify it, organisations should be asking whether comfort has been given sufficient consideration during the selection process.


Comfort should no longer be viewed as a secondary consideration alongside protection. When garments are lightweight, breathable and designed to be worn as part of a complete flame-resistant clothing


THE MISSING LAYER IN ARC FLASH PROTECTION


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