A Critical Safety Update
A quick rundown on OSHA’s recent arc flash guidance.
- By David Kopf
- Mar 14, 2025
For the first time in nearly two decades, OSHA updated its arc-flash hazard guidance on Nov. 25, 2024. This update provides clear instructions for both employers and workers, emphasizing two major risks: misidentifying energized work as de-energized and unsafe practices around low-voltage equipment.
Online, Occupational Health & Safety magazine covered the update in our enewsletter, site, webinars and podcast, but I want to use this print column to underscore some key elements from the guidance:
1. Low-Voltage Hazards. One of the major misconceptions in electrical work is that low-voltage systems are inherently safe. The updated guidance clarifies that voltage level is not the determining factor in the severity of an arc-flash incident. Rather, amperage, cycle time, and worker proximity play critical roles. A 120/208-volt system can still generate enough energy to cause catastrophic burns and fatalities.
2. Personal Protective Equipment (PPE) and Arc-Rated (AR) Clothing. The guidance reinforces the importance of PPE, requiring arc-rated clothing, rubber insulating gloves, leather keepers, hard hats, face shields, and insulated tools where applicable. Arc-rated clothing must not only resist ignition but also insulate the wearer from burns. PPE is the last line of defense when all other safety measures fail.
3. Hierarchy of Controls. Following the established hierarchy of controls is paramount. This includes eliminating hazards, substituting safer equipment, implementing engineering controls, and enforcing administrative controls. OSHA urges workers and employers to prioritize these controls over protective gear, which should be the final safeguard.
4. Worker Participation and Training. Lack of awareness is a major contributing factor to arc-flash incidents. OSHA’s update stresses ongoing training and hazard recognition, ensuring workers understand the risks and how to mitigate them effectively. Employers must provide clear guidance on identifying and avoiding electrical hazards.
5. Establishing Boundaries. The guidance reinforces the need to maintain appropriate approach boundaries. Workers who are not properly trained or equipped should not enter restricted areas where arc-flash hazards exist. Clear signage and demarcation help prevent accidental exposure to dangerous energy sources.
6. Clarification on De-Energized Work. Many electricians falsely believe they are working on de-energized equipment when, in reality, they are not. OSHA estimates that more than 90 percent of workers claiming to perform de-energized work do not meet the proper standards. Proper lockout/tagout procedures, voltage testing, and the use of PPE until equipment is confirmed de-energized are critical steps.
By implementing these new safety measures, employers can help shift the paradigm — ensuring that proper precautions are the standard, not the exception. For more details, visit OSHA’s Arc Flash Guidance Page at www.osha.gov/electrical/flash-hazards.
This article originally appeared in the February/March 2025 issue of Occupational Health & Safety.
About the Author
David Kopf is the publisher and executive editor of Occupational Health & Safety magazine.