Arc Flash PPE Care: 2025 Guide (Part 3 – Essential Dos, Don’ts, and Lifesaving Maintenance Tips for Maximum Protection)
If you think buying arc-rated PPE is enough to keep you safe from arc flash hazards, think again. Even the best flame-resistant clothing, gloves, helmets, and face shields only work if they are used correctly, maintained regularly, and inspected properly. Neglect, improper cleaning, or hidden damage can compromise your safety and put you at serious risk of burns, electrical injuries, or worse.
This guide breaks down everything you need to know about the proper use and care of arc flash PPE — from dos and don’ts to a step-by-step inspection checklist for every item in your safety kit. Whether you’re an electrician, industrial maintenance worker, or safety officer, these best practices will help you maximize protection, extend the life of your gear, and stay compliant with OSHA, NFPA 70E, IEC 61482, and SANS 724 standards.
You’ll learn:
- Who Wears Arc Flash PPE and When?
- Proper Use and Care of Arc Flash PPE
- Arc Flash PPE Maintenance Checklist
- Protect Your Life with Proper PPE Use and Care
- Frequently Asked Questions (FAQs)
Think of this as your practical, everyday guide to arc flash PPE safety – because the right gear, properly cared for, can literally be the difference between walking away safely and serious injury.
WHO WEARS ARC FLASH PPE AND WHEN?
Arc flash PPE isn’t everyday workwear, it’s task-specific protection. Workers don’t need to wear heavy suits all day, but when a job involves energized equipment, high fault currents, or panel testing, PPE is non-negotiable.
Examples of when arc flash PPE is required:
- Operating live electrical panels.
- Servicing switchgear or transformers.
- Performing energized testing or troubleshooting.
- Working in substations, power plants, or mining operations.
Who needs it besides electricians?
- Utility workers repairing power lines.
- Industrial maintenance teams servicing heavy machinery.
- Miners using high-powered underground equipment.
- Oil & gas workers managing hazardous area electricals.
- Construction teams using temporary power systems.
📌 Employer responsibility: Provide PPE, ensure proper fit, and train workers on correct use. Workers must inspect and wear PPE as instructed.
PROPER USE AND CARE OF ARC FLASH PPE: DOS, DON’TS, AND INSPECTION CHECKLIST
Arc-rated PPE is an essential line of defence against electrical hazards. But its protection is only as reliable as its upkeep. Neglect or improper care not only reduces performance but puts lives at risk. Below is a comprehensive guide to maintaining arc flash PPE – what to do, what to avoid, and how to check each item.
DO: Best Practices for PPE Care
- Follow Manufacturer’s Instructions
Every item has specific care and cleaning guidelines. Always refer to the user manual or tag before washing or drying. Some materials may require industrial laundering. - Wash Regularly and Correctly
Use warm water and mild, non-abrasive detergent. Machine-wash garments separately on a gentle cycle to avoid fabric damage. Remove sweat, oils, or contaminants that reduce flame resistance. - Inspect PPE Before and After Use
Check each component for:- Holes, tears, fading, or thinning of fabric
- Burns, scorch marks, melted spots
- Damaged or missing fasteners, zippers, or Velcro
- Cracked or clouded visors
- Crumbling rubber on gloves
- Worn or punctured soles on boots
- Store Properly
Keep PPE in a dry, cool, and dark location, and keep away from:- Direct sunlight
- Heaters or radiators
- Dust, chemicals, or moisture
- Sharp objects or tools that can damage fabric
- Clean Face Shields, Visors, and Goggles Gently
Use water and a soft, lint-free cloth. Avoid rubbing with paper towels or wiping while dry. - Use a Maintenance Log
Maintain a tracking sheet for PPE inspection dates, issues found, repairs, and replacements. This boosts compliance and user responsibility. - Assign PPE to Individuals
Avoid shared gear where possible. Personalized assignment prevents overuse, promotes accountability, and ensures proper fit.
DON’T: Common Mistakes That Damage PPE
- Don’t Use Household Bleach or Fabric Softeners
These chemicals destroy FR (Flame-Resistant) properties and may render clothing ineffective in a flash event. - Don’t Use Alcohol-Based Wipes or Sprays on Garments
Many disinfectants are flammable or corrosive to protective fibres. - Don’t Share Uncleaned PPE Between Workers
This spreads contamination, sweat, and pathogens, especially on helmets, gloves, and earmuffs. - Don’t Dry PPE on Open Flames or Heaters
High heat can shrink or melt FR materials. Tumble dry on low or hang-dry naturally, per instructions. - Don’t Iron Arc-Rated Garments
Heat pressing or ironing may reduce arc protection or ignite residues. - Don’t Ignore Small Damage
Even a small tear can compromise the integrity of the PPE. Minor issues grow quickly, replace your PPE when in doubt.
Arc Flash PPE Maintenance Checklist
| PPE Item | What to Inspect | Care & Maintenance Tips |
| FR Clothing | Tears, holes, fraying, fading, oil or chemical stains | Machine-wash with FR-approved detergent. No bleach, no softeners. Air dry or tumble dry on low. |
| Rubber Gloves | Cracks, discoloration, punctures, stiffness, sticky feel | Store in a cool, dry bag; air test before use; clean with warm water and mild soap. Replace if compromised. |
| Leather Protectors | Cuts, burns, hard spots, signs of drying out | Use leather conditioner occasionally. Never wash in water. Store flat or hanging. |
| Face Shields & Hoods | Scratches, cracks, discoloration, clouding of visor | Use water and microfiber cloth to clean. Never use abrasive cleaners. Store in protective case. |
| Hard Hats / Helmets | Cracks, dents, faded shell, damaged suspension | Replace every 5 years (or sooner if damaged). Clean with soap and water only. |
| Boots (Dielectric/Insulated) | Sole wear, toe cap damage, loss of traction | Clean mud and dirt regularly. Air dry. Store away from sunlight. Replace if cracked or burned. |
| Hearing Protection (Earmuffs/Earplugs) | Deformation, loss of elasticity | Replace disposable plugs after each use. Clean earmuffs with mild soap. Discard if they no longer seal properly. |
| Labels & Certifications | Missing or illegible tags | If arc-rating, manufacturing date, or care instructions are unreadable – the item is non-compliant. Replace immediately. |
| Zippers, Velcro, Closures | Stuck, broken, worn out | Clean Velcro of debris. Repair or replace faulty closures to maintain garment fit and protection. |
Protect Your Life with Proper PPE Use and Care
Arc flash PPE is not just another piece of work gear, it’s a lifesaving shield. Proper use, care, and regular inspection are non-negotiable. Even the highest-rated arc-rated clothing and gear cannot protect you if it is worn out, improperly cleaned, or damaged.
By following best practices, avoiding common mistakes, and maintaining a detailed inspection checklist, you ensure that your PPE is always ready to perform when you need it most. Remember: neglecting PPE maintenance can be the difference between walking away safely and suffering life-altering injuries.
A strong PPE culture not only safeguards employees but also ensures compliance with South African standards (SANS 474, SANS 724) and international regulations like NFPA 70E and IEC 61482. Investing time in proper
Frequently Asked Questions (FAQs) About Arc Flash Safety in South Africa
1. How should arc flash risk assessments be conducted in South African workplaces?
Arc flash risk assessments identify potential hazards, calculate incident energy levels, and define safety boundaries (restricted, limited, and arc flash). These assessments should follow SANS 474 guidance, NFPA 70E principles, and consider both low- and high-voltage equipment.
Only competent personnel should perform these assessments, and results must be documented and periodically reviewed (every 3–5 years or after major system changes).
📌 Learn more:Department of Employment and Labour – Electrical Safety Guidelines
2. What are the legal PPE requirements for electrical workers in South Africa?
The Occupational Health and Safety Act (OHS Act, 1993) and SANS 724 set the minimum PPE standards. Arc-rated PPE must match the calculated incident energy (Cal/cm²) for the task, including:
- Arc-rated clothing (shirts, pants, or full suits)
- Arc-rated helmets with face shields and balaclavas
- Insulated gloves with leather protectors
- Dielectric or arc-rated boots
- Hearing protection for high-noise environments
Employers must ensure PPE fits correctly, is regularly inspected, and that workers are trained on proper use.
📌 Learn more:SABS – Standards Catalogue
3. Can technology reduce arc flash risk, and what systems are available locally?
Yes. Modern technology enhances prevention and worker safety:
- Infrared thermography: Detects overheating equipment before faults occur.
- Arc flash relays and sensors: Trip circuits in milliseconds to prevent energy release.
- Remote racking systems: Allow breakers to be operated from a safe distance.
- Predictive maintenance software: Alerts teams to potential failures before they escalate.
Many South African companies adopt these solutions in compliance with SANS 474 and NFPA 70E.
📌 Learn more:SAIEE – Electrical Engineering Safety Resources
4. How can SMEs implement arc flash safety without a large budget?
Small and medium enterprises can improve safety cost-effectively by:
- Conducting staff training on hazard recognition and safe practices
- Using SANS-compliant labels and signage for high-risk areas
- Purchasing PPE in phases or through rental schemes
- Conducting routine inspections and maintenance rather than waiting for failures
Prioritize high-risk equipment first, and expand programs over time to meet OHS compliance.
📌 Learn more:Electrical Contractors Association of South Africa (ECA-SA)
5. What are the consequences of failing to comply with arc flash safety regulations?
Non-compliance carries serious risks:
- Legal penalties: Fines, stop-work orders, or enforcement action by the Department of Employment and Labour
- Civil liability: Injured workers can sue for damages
- Reputation loss: Unsafe practices deter clients and investors
- Insurance issues: Higher premiums or denial of claims
Compliance protects employees, ensures operational continuity, and reduces financial and reputational risk.
📌 Learn more:OHS Act – Department of Employment and Labour
NEXT STEPS – TAKE ACTION
Don’t compromise on workplace safety. Whether you’re an employer, safety officer, or procurement manager, always:
• Source PPE from trusted, SABS-approved suppliers
• Request and verify compliance certificates before purchasing
• Train staff to recognize and properly use genuine certified PPE
• Implement a regular PPE inspection and maintenance schedule
💡Take action today: Ensure your team is fully protected, compliant, and prepared for any arc flash hazard. Proper PPE saves lives – make safety a priority now.
CONTACT US
Don’t compromise on safety, partner with experts who understand South African standards and international best practices.
📧 Email: support@realppe.co.za
📞 Call: +27 11 568 4247
🌐 Visit:www.realppe.co.za to browse our full range of certified PPE, request a safety consultation, or connect with a knowledgeable safety advisor today.
Remember: Buying PPE is only half the battle – proper use, training, and maintenance save lives. Buy certified. Buy smart. Buy from RealPPE.