Fall hazards and electrical risks are both well-known dangers in industries including utilities, petrochemical, construction, and oil and gas.  But what happens when they occur at the same time? In an instant, a powerful electrical explosion can melt or ignite a standard harness, leaving the worker exposed not only to the risk of severe burns but also to the risk of a potential fall. Workers who work at height where electrical risks are present may need fall protection PPE that is specifically designed to withstand the extreme heat and energy of an arc flash.

Understanding what an arc flash is, why it poses a danger, and the regulations governing specialized arc-rated PPE can help keep workers protected in these hazardous environments.

What Is an Arc Flash?

According to the Occupational Safety and Health Administration (OSHA), “An electric arc is a type of electrical explosion. The electric arc produces a bright flash of hot gas, where temperatures can exceed 35,000 °F (19,400 °C), nearly four times the heat of the sun’s surface. The energy released in the arc rapidly heats and vaporizes the metal conducting the electricity, producing an explosive arc blast resulting in deafening noises, supersonic concussive forces, and super-heated shrapnel.”¹

Arc flash dangers include:²

• Severe burns from radiant heat or ignited clothing
• Blindness from the intense flash of light
• Hearing damage from the explosion-like sound
• Physical trauma from pressure waves or flying debris

An arc flash is unpredictable and can happen anywhere workers handle or maintain energized electrical equipment. Even workers who do not directly handle electrical systems can be exposed if they are in the vicinity of an arc flash event. The proper PPE can reduce the risk of life-threatening injuries.

What are the OSHA and NFPA Arc Flash Standards and Regulations?

Regulatory agencies set strict standards aimed at helping to protect workers from arc flash hazards. These regulations are designed to help prevent serious injuries and fatalities by ensuring that employers provide a safe work environment and proper protective equipment.

OSHA 29 CFR 1910.269 and 29 CFR 1926: Employer Guidelines for Arc Flash Risks

OSHA sets the foundation for arc flash safety³ in both general industry⁴ and construction regulations,⁵ outlining the following guidelines to employers to help enhance worker safety:

• Identify and assess arc flash hazards in the workplace.
• Assess the workplace to identify employees exposed to hazards from flames or from electric arcs.
• Ensure workers wear PPE rated for the level of arc flash exposure they may encounter.
• Train employees on recognizing arc flash risks and using protective equipment properly.
• Establish safe work procedures to minimize the likelihood of an arc flash event.

These guidelines apply across industries where electrical hazards are present, including utilities, manufacturing, and industrial maintenance.

NFPA 70E: Workplace Electrical Safety Practices

The National Fire Protection Association (NFPA) 70E standard outlines comprehensive workplace safety practices for handling energized electrical systems.⁶ NFPA “helps companies and employees avoid workplace injuries and fatalities due to shock, electrocution, arc flash, and arc blast, and assists in complying with OSHA 1910 Subpart S and OSHA 1926 Subpart K.”⁶

Key elements include:

• Arc Flash Risk Assessments: Requires employers to determine the potential severity of an arc flash event and label electrical equipment with incident energy levels.
• Arc Flash Boundaries: Defines safe distances where workers must wear PPE or de-energize equipment before performing tasks.
• Hierarchy of Controls: Encourages eliminating hazards when possible, such as using remote operation tools or scheduling maintenance when circuits are de-energized.

NFPA 70E also assigns Arc Flash PPE Categories (1-4) based on the level of incident energy exposure, helping workers select the appropriate protective gear. Under NFPA 70E, fall protection used in these environments must meet or exceed these ratings.

ASTM F887: Arc Flash Testing for Fall Protection PPE

ASTM F887 is the standard that specifically applies to fall protection harnesses and lanyards used in arc flash-prone environments.⁷  To meet this standard, fall protection equipment must:

• Withstand an arc flash exposure of 40 cal/cm² without igniting or melting.⁸
• Pass drop tests after arc flash exposure to ensure the harness can still arrest a fall.
• Use materials that self-extinguish within five seconds to prevent fire hazards.

Unlike general arc-rated clothing, which is designed to help protect against burns, ASTM F887 ensures that fall protection gear remains functional after an arc flash event. If a harness fails, a worker could be left unprotected against falls, compounding the risk of serious injury.

How Do OSHA’s November 2024 Updates to Arc Flash Protection Impact Compliance?

In response to evolving workplace hazards, OSHA released updated Arc Flash guidance in November 2024.⁹ These updates emphasize:³

• Regular PPE hazard assessments: “Employers must select appropriate PPE for their workers based on the calculated incident energy, ensuring they are protected from potential arc flash hazards in accordance with 29 CFR 1910.269(l)(8)(v) and 29 CFR 1926.960(g)(5).”³
• Clear labeling and warnings: “Lack of proper warning systems, such as warning signs and labels,” is identified as one of the conditions that can lead to arc flash incidents.³
• Training expectations: “Ensure that employees performing the electrical tasks are adequately trained, competent, and certified.”³

With these updates, safety managers are working to ensure their fall protection programs align with both OSHA regulations and industry standards. Staying compliant isn’t just about avoiding penalties, it’s about equipping workers with gear that can help protect them when it matters most.

Considerations for Choosing Proper PPE for Hot Work Applications

Most harnesses and connecting devices are designed to help prevent falls, but they may not necessarily be built to withstand the conditions created by an arc flash. When selecting fall protection for applications with arc flash hazards, factors that safety professionals may want to consider include:

• ASTM F887 and NFPA 70E compliance: Verifies the harness and lanyard meet arc flash protection standards.
• Flame-resistant webbing and components: Prevents ignition and melting during an arc flash.
• Self-extinguishing materials: Stops flames from spreading after exposure to extreme heat.
• Durability under high temperatures: Maintains strength to prevent fall-related injuries.

MSA provides industry-leading fall protection solutions designed specifically for hot work applications. Our arc flash-rated fall protection solutions include:

• MSA V-FIT® Arc Flash Harness: ASTM F887-certified for arc flash protection, features MSA’s innovative blend that allows for a softer, more flexible webbing for enhanced comfort.
• MSA V-FORM® Arc Flash Harness: One of the lightest Arc harnesses MSA has ever created. An optimized design and patented configurations provide enhanced comfort and flexibility, so you can focus on the toughest jobs.
• MSA V-TEC® Arc-Rated PFL: Features several intuitive labeling and color-coding design elements to help simplify selecting the appropriate device for the job and worksite. V-TEC Arc Flash PFLs meet the ANSI Z359.14-21 standard and are available in both single-leg and twin-leg configurations.

Explore MSA’s most popular fall protection PPE, including arc flash solutions, available for same or next day shipping: https://us.msasafety.com/need-it-now

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Sources:

1. https://www.osha.gov/electrical/flash-hazards
2. https://www.osha.gov/sites/default/files/publications/OSHA4474.pdf
3. https://www.osha.gov/sites/default/files/publications/OSHA4472.pdf
4. https://www.osha.gov/laws-regs/regulations/standardnumber/1910/1910.269AppE
5. https://www.osha.gov/laws-regs/regulations/standardnumber/1926/1926.960
6. https://www.nfpa.org/codes-and-standards/nfpa-70e-standard-development/70e
7. https://store.astm.org/f0887-23.html
8. https://www.ishn.com/articles/104126-astm-standard-tests-ppe-osha-rule-aims-to-eliminate-hazards
9. https://www.globenewswire.com/news-release/2024/11/25/2986938/0/en/Occupational-Safety-and-Health-Administration-OSHA-Issues-New-Arc-Flash-Hazard-Guidance.html