Arc Flash in Utilities: Personal Fall Arrest Systems in an Electrical Environment

The electrical utility industry deals with some unique safety challenges that many never consider. Whether working from wood poles, bucket trucks, steel towers, or substations, the combination of an outdoor, energized environment coupled with extreme heights makes fall hazard mitigation a little more complex.  

A Personal Fall Arrest System (PFAS) like a body harness and lanyard must not only protect workers against falls, but it must also withstand arc flash hazards, electric shock, inclement weather, and long-term UV exposure. Professionals who depend on this equipment need to consider a wide variety of factors when choosing their fall protection equipment.

Arc Flash

An arc flash is an extremely explosive release of electrical energy through the air. It occurs when current flows through an unintended path, such as a short circuit or fault. Its explosion produces intense heat and pressure that can instantly engulf everything into flames, melting fabric and spraying molten metal over 20 feet away.

The intensity of an arc flash is not determined by the voltage, but the amount of available current or amperage) in the circuit. This is why lower, secondary voltage circuits can be so dangerous. Workers may have a false sense of security around the lower voltages but the potential for a more serious arc flash is magnified many times where the amperage is high.  

Why Standard Fall Arrest Equipment Isn’t Enough

Standard fall arrest equipment is not built for the extreme heat of an arc flash. Polyester harnesses and lanyards will melt or catch fire during an event, leaving a worker without protection when it may be needed the most.

Arc-rated gear is different. It uses heat- and flame-resistant aramid fibers, such as Kevlar®, Nomex®, and Technora®. These materials hold up to the intense heat, so the equipment survives the blast and stops the fall. It’s important to remember that arc-rated fall protection equipment is designed to protect only the gear, not the worker’s body.

Key Safety Standards

OSHA sets the foundation for fall protection, but other organizations define how gear should perform against fall and electrical hazards.

ANSI (American National Standards Institute)

The ANSI Z359 Fall Protection Code outlines how harnesses, lanyards, and self-retracting lifelines (SRLs) should be designed and tested.

Recent updates to ANSI Z359.14 clarified SRL classifications:

• Class 1 SRLs anchor at or above the D-ring.
• Class 2 SRLs anchor at, above, or up to five feet below the D-ring, safe for leading-edge environments

ANSI also introduced personal SRLs (SRL-Ps) as a category. These are SRLs that attach directly to the harness.

These updates matter for utility crews who often prefer personal SRLs to reduce fall distances and provide more mobility in tight spaces.

(Note: Some Class 1 SRLs can be used below the D-ring in bucket trucks if there are no leading-edge hazards.)

ASTM (American Society of Testing and Materials)

ASTM F887 sets performance standards for arc-rated harnesses and lanyards. Equipment must withstand 40 calories per square centimeter of heat, the same protection level as the strongest flame-resistant clothing.

Gear is exposed to an arc flash and then drop-tested to confirm it still works. While the standard covers harnesses and lanyards, some manufacturers such as FallTech also test their SRLs to the same level for added safety.

Together, ANSI Z359 and ASTM F887 help ensure that workers have gear that protects against both falls and high heat.

Using Technology

Today’s arc-rated fall protection equipment utilizes advanced technology to improve safety, comfort and durability to withstand the harsh electrical utility environment.

Common materials include:

• Technora: Synthetic, aramid fiber often used to achieve flame resistance and durability in ropes.
• Kevlar and Nomex blends: Combine strength, heat resistance, and UV protection.
• ABS plastics: Excellent dielectric insulation properties and thermal barrier protection.

Eliminating Secondary Contact Burns

The intense radiant heat of an arc flash can make metal hardware on a harness hot enough to cause secondary contact burns to a victim’s skin. To eliminate that hazard, protective barriers are used between the potentially hot metal and the person’s body.

Protective barriers include:

• Leather pads that block contact with the metal.
• Kevlar webbing D-ring loops that remove metal all together.
• Over-molded ABS plastic hardware that creates a barrier with the bonus of providing dielectric insulation usually rated between 4 and 9kv.

Best Practices

Equipment and standards are only part of the solution. Real safety depends on habits and awareness:

1. Assess hazards: Check for fall and arc flash risks before starting work.
2. Use the right gear: Choose arc-rated harnesses, lanyards, or SRLs designed for electrical environments.
3. Education: Understand how arc flash occurs and know how to mitigate the hazard. Know the capabilities and limitations of your personal fall arrest system.  
4. Inspect before each use: Remove gear that has been exposed to an arc flash or used to stop a fall.

Product Advancements

As technology advances, arc-rated equipment continues to evolve with it.

Future trends in arc-rated fall protection include:

• Lighter materials that reduce weight without losing strength.
• More comfortable harnesses that improve fit and reduce fatigue.
• Smart PPE that monitors temperature, energy exposure, or fall events.
• Better alignment between OSHA, ANSI, ASTM, and the National Fire Protection Association’s NFPA 70E standard for consistency.

Electrical utility workers are the front line of safety innovation. The hazards they are exposed to everyday require PFASs that are safer, lighter, smarter, and better than ever before.

Working with live power requires trust in your equipment. Find out how FallTech makes utility work safer and easier on our Utilities Page.