Arc Flash PPE Checklist: What You Need to Stay Compliant in 2025
Your complete guide to choosing, assessing and maintaining your arc flash PPE checklist to meet 2025 regulations
To stay compliant with 2025 arc flash safety standards, your PPE must be certified to recognised ratings like ATPV or ELIM (IEC 61482), matched to your site’s incident energy level, and properly maintained. Use our step-by-step checklist to cover suits, hoods, gloves, and accessories, ensure the right fit, inspect regularly, and keep your documentation up to date. This guide helps you meet guidelines, HSE, and IEC requirements with confidence.
Why You Need an Arc Flash PPE Checklist for 2025
With changes to arc flash safety standards taking effect in 2025, many businesses are unsure whether their current PPE still meets legal and technical requirements. It is no longer enough to issue basic flame-resistant clothing and assume your team is protected.
Whether you’re updating an existing programme or starting from scratch, this checklist will help you make informed decisions and avoid common compliance gaps.
For technical guidance and certified gear, visit our ARC Workwear collection.
Understanding Arc Flash Risk
An arc flash is a sudden release of electrical energy that produces intense heat, light and pressure. In less than a second, it can reach temperatures hotter than the surface of the sun. The result can be serious injury, including burns, hearing damage, and permanent vision loss.
How to Assess Arc Flash Risk
To choose the right level of protection, you need an accurate risk assessment. This includes:
- Incident energy calculation using the IEEE 1584 standard, which considers factors like fault current, system voltage, and working distance.
- PPE selection guidance from NFPA 70E (though US-origin, it is good practice throughout the UK), which outlines risk categories and the required arc-rated clothing for each level.
- Legal compliance with the Health and Safety at Work Act, which requires UK employers to carry out formal hazard assessments and implement appropriate controls.
Understanding your site’s arc flash risk is the first step in selecting PPE that meets safety and legal standards.
PPE Standards and Certifications
Arc flash protective clothing must do more than just look compliant. To offer genuine protection, it needs to be tested and certified against internationally recognised standards.
These standards make sure that each garment performs reliably under extreme conditions.
Key Arc Flash Testing Standards
IEC 61482-1-1
Measures two critical values:
- ATPV (Arc Thermal Performance Value) indicates the maximum incident energy the garment can withstand before causing second-degree burns.
- ELIM is the highest energy level at which no injury occurs under standard test conditions.
IEC 61482-1-2
Also known as the box test, this method simulates an open arc scenario. Garments are classified as:
- Class 1 for 4kA
- Class 2 for 7kA exposure
ASTM and EN ISO standards
These cover additional safety aspects such as flame resistance, seam integrity, fastener strength, and fabric durability.
UK Regulatory Expectations
In the United Kingdom, the Health and Safety Executive (HSE) sets clear expectations for managing arc flash risks. Employers must:
- Carry out a formal assessment of arc flash hazards on-site
- Provide PPE that matches the calculated incident energy level
- Train all relevant staff on how to wear and care for the equipment
- Keep accurate records of testing, inspections, and training
Following these rules is not just about ticking boxes. It is about protecting people. When arc flash incidents happen, the right PPE can be the difference between a near miss and a life-changing injury. Getting it right means giving your team the best chance to go home safely every day.
Arc Flash PPE Checklist for 2025 Compliance
Use this arc flash PPE checklist to build a PPE programme that not only meets 2025 regulations but also protects your team in real-world conditions:
1. Arc-Rated Clothing
- Select coveralls or two-piece suits with an ATPV or ELIM rating above your calculated incident energy.
- Look for flame-resistant fabrics and consider multi-layer designs for higher-risk environments.
- Always check labels and certifications to confirm the garment meets the required standards.
2. Hoods and Helmet Systems
- Choose arc flash hoods or face shields that offer full coverage of the head, face and neck.
- Confirm they are compatible with your existing helmet systems and tested to IEC 61482-1-2, Class 1 or Class 2.
3. Arc Flash Protective Gloves
- Match glove ratings to the level of arc energy risk in your task or environment.
- Opt for materials like Kevlar or leather blends that balance protection with flexibility.
- Replace gloves regularly if they show signs of wear or degradation.
4. Additional PPE
- Use FR base layers to prevent flammable clothing from igniting underneath arc gear.
- Include balaclavas, arc-rated boots, and outerwear based on job roles and conditions.
- Make sure each item is certified to relevant standards, not just the outer layer.
5. Proper Fit and Comfort
- Poorly fitting gear can reduce protection and increase risk. Offer full-size ranges and inclusive options for all body types.
- Hazchem’s mobile sizing van is available for convenient on-site fittings across the UK.
6. Maintenance and Inspection
- Perform daily visual checks to spot damage, contamination or wear.
- Arrange for annual assessments by qualified professionals.
- Keep a clear record of PPE usage, laundering and certification to support compliance and audits.
By following this checklist, you can build a reliable arc flash PPE programme that protects your team, meets 2025 regulations, and stands up to real-world demands. Small steps now can make a big difference when it matters most.
Best Practices for 2025 Compliance
Compliance goes beyond supplying the right equipment and ticking boxes for the arc flash PPE checklist. A proactive approach helps protect your workforce and keeps your organisation aligned with changing safety standards. Here are four key areas to focus on:
- Training: Make sure every worker understands arc flash risks, knows how to use their PPE correctly, and is confident in recognising when equipment needs replacing.
- Record Keeping: Maintain clear, digital records of PPE purchases, inspections, training sessions, and certification updates to stay audit-ready at all times.
- Stay Updated: Keep an eye on evolving standards such as NFPA 70E and IEC 61482. What is compliant today might not be sufficient tomorrow.
- Work with Reliable Suppliers: Partnering with a trusted provider like Hazchem gives you access to compliant products, expert advice, and tailored services such as on-site fittings and hazard assessments.
Final Thoughts on Your Arc Flash PPE Checklist
With the 2025 arc flash regulations now in force, businesses need to move beyond basic compliance and focus on maintaining a robust, ongoing PPE programme. This means choosing equipment that reflects the actual risks on site, keeping records up to date, and training staff to use PPE correctly.
A structured arc flash PPE checklist helps ensure nothing is overlooked, from certifications and fabric ratings to fit, maintenance and inspection schedules. Regular reviews are essential, especially as tasks or site conditions change. Taking a systematic approach not only supports compliance but also helps reduce the risk of incidents and strengthens overall safety performance across your operation.
Ready to upgrade your arc flash protection for full compliance in 2025?
Speak to our PPE specialists for expert advice, product recommendations, and on-site sizing support. We’ll help you build a compliant kit that works for your team, your risks, and your budget.