Navigating OSHA’s Arc Flash Guidance: What You Need to Know

OSHA’s revisions underscore the increasing urgency to implement robust, up-to-date safety practices in workplaces where electrical exposure is a risk.

• By Jeff DuLong
• Sep 08, 2025

Arc flash events remain one of the most dangerous hazards facing electrical workers, capable of causing catastrophic burns, serious injuries, or even fatalities. According to the NFPA (National Fire Protection Association), it is estimated that approximately 5 to 10 arc flash incidents occur per day in the United States, totaling roughly 1,800 to 3,650 incidents per year. While industry standards have long addressed these risks, many workers have continued to operate without the proper personal protective equipment (PPE). 

A common misconception dispelled by OSHA’s new guidelines, is that low voltage environments do not require proper PPE and are of lower risk to electrical workers, but this is not true. Workers who are exposed to any level of voltage are still at risk and proper PPE is required to ensure safety and proper protection.  

The Occupational Safety and Health Administration (OSHA) introduced updated arc flash safety regulations late last year. These revisions are designed to close longstanding protection gaps and ensure electrical safety protocols reflect current insights into arc flash hazards. 

This regulatory shift underscores the increasing urgency to implement robust, up-to-date safety practices in workplaces where electrical exposure is a risk. 

This new change in OSHA guidelines highlighted a staggering statistic: 600,000 workers were not adequately protected with the proper PPE to prevent injury from arc flash hazards. The new guidelines, effective immediately, outline several steps towards ensuring workers are protected, emphasizing the need for updated flame-resistant protective apparel.  

Thankfully, arc flash gear manufacturers for electrical PPE have innovated to ensure gear is in alignment with these new guidelines and without sacrificing performance. Workers can find comfort in knowing the gear is specifically designed to protect them in any voltage environment. Well-designed flame-resistant gear addresses protection, comfort, and should not cause PPE fatigue. 

OSHA outlined several critical areas for employers and safety professionals to consider:  

• Enhanced PPE Requirements. Underlines the use of arc-rated (AR) clothing and personal protective equipment (PPE) to protect against arc flash hazards. This includes specific guidelines on the types of PPE required for different levels of exposure. To avoid improper gear use and further risk, PPE managers should properly train workers on the correct use and placement of equipment. 
   

• Clarification on De-energized Work. Stresses that de-energized work is not the same as Lockout/Tagout (LOTO) or Electrically Safe Work Condition (ESWC). It requires an energized work permit and appropriate PPE. 
   

• Low Voltage Hazards. Highlights the dangers of low voltage (120/208, 277, etc.) work, debunking the myth that low voltage is not hazardous. It mandates the use of PPE even for low-voltage tasks. 
   

• Administrative Controls. Recommends administrative controls to prevent arc flash incidents, such as proper training, hazard identification, and assessment. 
   

• Worker Participation. Encourages active participation from workers in safety programs to identify and mitigate arc flash hazards. 

While not federally mandated, these guidelines should be seriously considered. These updates are intended to improve workplace safety and provide comprehensive protection for electrical workers. If you need to talk dollars and cents with management, consider this: a single arc‑flash injury that requires hospitalization can accrue direct medical expenses that could get into the several hundreds of thousands of dollars, depending on the severity of injuries.  

Implications for Safety Professionals

With the new directive in force, OSHA compliance officers have been instructed to give electrical‑safety programs heightened scrutiny during general industry inspections. Expect auditors to request a paper trail that proves not only that hazards were identified but that corrective actions were completed and verified. At minimum, safety professionals need to conduct a thorough review of existing safety protocols within their organizations.  

Safety professionals should consider revisiting or updating the following:  

• Evaluate Current PPE Programs. Assess whether the current PPE aligns with the updated requirements and provides adequate protection against identified hazards. If you're not currently considering or protecting against low voltage hazards, updates should be made immediately. If your workforce is outfitted in proper PPE, use this time to take inventory. Check garments for holes, stains and residue that could be impacting their performance.  

• Enhance Training Programs. Ensure that training materials and sessions reflect the new guidelines, fostering a culture of safety awareness and compliance. For workers who have already undergone training, make sure to communicate the updates to them. Best practice. everyone should be informed. 

• Conduct Comprehensive Hazard Assessments. Regularly perform detailed evaluations of potential arc flash risks, incorporating the latest OSHA recommendations. Regular hazard testing can mitigate potential arc flash risks that may otherwise go undetected. 

• Promote Worker Engagement. Facilitate open communication channels for workers to report hazards and participate in safety planning, reinforcing their role in maintaining a safe work environment. Workers’ participation is key in finding solutions before they become hazardous.  

Together, We Can Improve Worker Safety

OSHA’s latest directive is more than guidance; it signals enforcement intent. By closing low‑voltage loopholes, tightening energized‑work rules and emphasizing program audits, the agency has raised the bar for electrical safety. Following OSHA guidance can significantly increase workplace safety and decrease hazards on the job. It should become a common practice for safety professionals to regularly check guidelines and keep up with industry standards.  

As the industry progresses, new standards and safety guidelines are implemented to ensure safety is keeping up with changes in the workplace and changes in technology. Through proper communication, education and preparedness, electrical workers and safety professionals can work together to prioritize worker safety against arc flash hazards.  

This article originally appeared in the September 2025 issue of Occupational Health & Safety.