Arc Flash Rated Clothing | NFPA 70E FR PPE Guide

By R.W. Hurst, Editor

Arc flash rated clothing is a critical component of personal protective equipment (PPE) for electrical workers exposed to high-energy electrical hazards. These garments are designed to resist the intense heat and thermal energy of incident energy events, protecting workers from serious burns and injuries. Arc-rated (AR) clothing must meet minimum safety thresholds defined by NFPA 70E and CSA Z462, including arc thermal performance values (ATPV) measured in cal/cm². Whether it’s a full-body suit or layered FR garments, the right clothing safeguards lives while supporting regulatory compliance and a strong electrical safety program.

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Types of Arc Flash Rated Clothing

The range of protective clothing includes coveralls, jackets, pants, face shields, and full-body suits. Depending on the task and the calculated incident energy level, workers may require simple AR shirts or comprehensive incident energy suits with integrated hoods, gloves, and moisture-wicking properties. Customization options such as breathable fabrics, reinforced seams, and ergonomic design help ensure that this protective clothing is safe and comfortable for extended use. If you're selecting gear for high-risk tasks, our Arc Flash Suit article covers materials, suit components, and selection tips.

Employer Responsibility Under OSHA and CSA Z462

Employers are legally obligated under OSHA regulations and Canadian standards to provide suitable AR PPE for workers in environments with electrical hazards. This includes educating workers on correct usage, maintenance protocols, and PPE replacement intervals. Regular hazard assessments and refresher training sessions are essential in maintaining a proactive electrical safety culture. Properly enforced PPE policies not only protect personnel but also reduce the risk of regulatory penalties and downtime due to injury.

Industry Standards and Advancements

Arc flash rated clothing continues to evolve with new materials, construction techniques, and enhanced functionality. The latest garments incorporate arc-rated fabrics tested to ASTM F1506 and IEC 61482-1-1 standards, offering improved protection and comfort. High-performance fabrics now include thermal-resistant garments that offer excellent breathability, flexibility, and sweat management. As NFPA 70E and CSA Z462 guidelines update every few years, it’s vital for safety managers to remain informed and adapt PPE programs accordingly. To understand the broader compliance standards that guide clothing selection, check out our NFPA 70E Chapter Summary.

Understanding Arc-Rated Protective Equipment

AR clothing is tested and rated for its ability to protect against the thermal energy of an electrical explosion. The arc rating, expressed in cal/cm², quantifies how much heat the fabric can absorb before causing a second-degree burn. All AR gear is flame resistant (FR), but not all FR garments meet US and Canadian standards. An arc thermal performance value (ATPV) label confirms the minimum protection level and compliance with safety benchmarks.

Key features of AR clothing:

Flame resistant, self-extinguishing materials
AR from 4 to 100+ cal/cm²
Compliance with NFPA 70E, CSA Z462, ASTM F1506
Single-layer and multi-layer options for various incident energy levels

For a summary of what equipment must be worn under each condition, visit Arc Flash PPE Requirements.

Arc Rating vs. Flame Resistance: What’s the Difference?

Many people confuse AR clothing with flame-resistant (FR) clothing, but they are not interchangeable. All AR garments are flame resistant, but not all FR garments have been tested for hazards.

AR clothing is tested according to standards such as ASTM F1506 and IEC 61482-1-1 to determine its ability to protect against explosive energy. This is expressed as an ATPV rating, which tells you how many calories of thermal energy per square centimeter the garment can safely withstand.

Meanwhile, flame-resistant clothing may protect against open flames but hasn't been validated under the same electrical hazard classification systems. To ensure safety, always look for garments labeled with a verified AR rather than just “FR.”

How to Tell the Difference Between Arc Rated (AR) and Flame Resistant (FR)

In 2012, NFPA introduced a terminology shift in how we refer to electrical protective clothing. What was commonly called Flame Resistant (FR) clothing is now properly referred to as Arc Rated (AR) clothing when it is tested and certified for worker protection. This change was made to help clarify an important distinction: while all AR garments are flame resistant, not all FR clothing has an arc rating.

The key difference lies in testing and certification. Flame-resistant clothing is generally intended to resist ignition and prevent garments from continuing to burn. However, AR clothing undergoes specific testing to determine how much thermal energy it can withstand in an uncontrolled energy event. This level of protection is measured using ATPV in calories per square centimeter (cal/cm²), and the rating is applied only to fabrics that have first passed flame resistance requirements.

FR fabrics are tested using the Vertical Flame Test, which evaluates how a fabric responds to direct exposure to flame under controlled conditions. But to qualify as AR, clothing must also meet standards such as ASTM F1506, ASTM F1959, and IEC 61482-1-1.

There are two primary reasons for wearing this type of PPE:

Ignition Resistance: In an accident, non-FR clothing can ignite and continue to burn on the body, increasing the extent of injury. AR clothing is designed to self-extinguish, reducing burn severity and preventing flame spread across the garment.

Thermal Insulation: AR clothing also provides insulation against second- and third-degree burns. It is engineered to block a significant percentage of thermal energy from reaching the skin during an electrical explosion.

Understanding that FR suit ratings and FR labels are not interchangeable is vital. An AR label confirms that the garment has been tested against electrical hazards. An FR label alone may not provide sufficient protection.

Before purchasing PPE, checking that the label includes an AR and confirms compliance with recognized arc flash standards is important. Proper maintenance is just as important—washing, storage, and inspection all affect the performance and lifespan of arc-rated clothing.

How to Verify Your Clothing Is Correct

ATPV in cal/cm²
Compliance with applicable safety standards
Manufacturer information and certification marks

Routine inspections should check for fabric degradation, tears, contamination, and expiration dates. Recordkeeping of inspection dates and replacement timelines ensures continued compliance and safety.

Our Arc Flash PPE Category page explains how hazard categories determine the clothing and protection required for each job.

Proper Usage and Fit of Electrical Hazard Gear

To be effective, arc flash rated clothing must fully cover the body. This includes AR shirts, pants, overalls, gloves, and face protection. Garments should fit well to avoid snagging or restricted movement. For high-energy tasks, layering garments or using incident energy suits is recommended. Ensure compatibility with other PPE components like rubber insulating gloves and dielectric footwear. To learn how different suit ratings impact protection, visit our 40 Cal Arc Flash Suit page, which details ATPV levels and use cases.

Why Arc Flash Clothing Matters

The consequences of an incident can be devastating. AR clothing:

Prevents serious burns and secondary injuries
Maintains compliance with NFPA 70E and CSA Z462
Reduces long-term medical complications
Boosts morale by showing commitment to worker safety

AR clothing is more than regulatory PPE—it’s life-saving equipment. By understanding arc ratings, proper selection, and usage guidelines, organizations can build a safer work environment for electrical professionals. As new technologies emerge and standards evolve, investing in advanced electrical hazard gear and maintaining NFPA 70E compliance remains a cornerstone of effective safety programs.