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Arc-Flash Boundaries & PPE Categories: Quick Field Checklist

Understand arc-flash boundaries and PPE categories at a glance. This quick field checklist helps you identify risk levels, select proper protective gear, and stay compliant with electrical safety standards.

LearnTastic
Jan 15, 2026

An arc flash is a hazardous event where electricity travels through the air to a conductor or the ground. It releases extreme heat, pressure, blinding light, loud sound, and toxic fumes. According to the National Fire Protection Association, the U.S. sees roughly five to ten arc flash incidents in electrical equipment daily. Causes include damage from dust or corrosion, or human error when equipment is not properly de-energized. These arc flashes are violent. To combat this, comprehensive arc flash safety training online is crucial for awareness. To assist you in evaluating procedures, we will discuss arc flash boundaries, Personal Protective Equipment (PPE) classifications, and an arc flash safety checklist in this blog.

What Are Arc Flash Boundaries?

The arc flash boundary (or flash protection boundary) marks the minimum safe distance from exposed, energized conductors that could cause an arc flash event. It is crucial to ensure worker safety before taking measurements, especially on energized equipment. Workers must know and respect the arc flash boundary at all times.

The boundary is calculated to 1.2 calories/cm² (5.02 J/cm2 ) of incident energy. This is the distance where a worker without the appropriate Personal Protective Equipment (PPE) would sustain second-degree burns. No worker should cross this boundary without the necessary NFPA 70E training online or offline and without wearing the required PPE.

The National Fire Protection Association (NFPA) recommends defining three boundaries to minimize electrical risk, detailed in NFPA 70E. Moving closer to the live equipment requires more arc flash safety training online or offline and higher levels of PPE. These include:

Arc Flash Boundary: This boundary changes based on the arc flash hazard and is calculated to 1.2 cal/cm². It is the furthest boundary if the limited approach boundary is closer. If it is the furthest, it becomes the line no one should pass without training and PPE.
Limited Approach Boundary: Moving inward, this boundary marks a point where a shock hazard is still possible. Qualified workers must wear appropriate PPE within this space. Non-qualified workers must stay outside unless escorted by a specially trained worker and wearing proper PPE.
Restricted Boundary: This is the area closest to the live, exposed equipment. Only qualified workers with proper training and PPE may cross this line. Work on the energized equipment within this boundary may also require a work permit and documentation.

PPE Categories Explained

Personal Protective Equipment (PPE) is the final line of defense against worker injury. Employers must provide adequate PPE, including arc-rated (AR) clothing, for the job.

Below are the four Arc Flash PPE Categories for those using NFPA 70E (2018) Table 130.7 instead of a full arc flash risk analysis.

Four Categories of Arc Flash PPE

An arc flash is a sudden, dangerous electrical explosion that releases intense heat. To protect workers from this hazard, safety standards use four specific PPE (Personal Protective Equipment) categories. These categories define the minimum protection level required for the clothing, measured by the Arc Rating (in cal/cm2).

Here is a table for PPE categories, classified based on the severity of the risk:

PPE Category	Minimum Arc Rating	Required Clothing	Layering	Required Head/Face Protection	Required Hand Protection
CAT 1	4 cal/cm²	AR Long Sleeve Shirt/Jacket and Pants OR AR Coverall	Requires a single layer of AR PPE	Face Shield (with wrap-around guard/balaclava) OR AR Suit Hood	Heavy-Duty Leather Gloves
CAT 2	8 cal/cm²	AR Long Sleeve Shirt and Pants OR AR Coverall	Often met with a single layer. Many opt for CAT 2 clothing for both CAT1&2 exposure.	AR Suit Hood OR AR Face Shield/Balaclava	Heavy-Duty Leather Gloves
CAT 3	25 cal/cm²	AR Flash Suit Jacket and Pants OR AR Coverall	Requires additional layers of PPE	AR Flash Suit Hood	Rubber Insulating Gloves & Leather Protectors OR AR Gloves
CAT 4	40 cal/cm²	AR Flash Suit Jacket and Pants OR AR Coverall	Requires AR clothing with a minimum 40 cal/cm2 rating.	AR Flash Suit Hood	Rubber Insulating Gloves & Leather Protectors OR AR Gloves

Note: Regular enrollment in a specialized PPE and electrical safety course minimizes these risks.

How to Strengthen Your PPE Selection

Choose PPE that matches the hazard level
Confirm arc ratings for electrical tasks
Inspect PPE before every use
Follow NFPA 70E requirements consistently

Arc Flash Safety: Quick Field Checklist

A precise arc flash study is vital for electrical safety and NFPA 70E/IEEE 1584 compliance. Accurate analysis requires detailed system information; missing data leads to underestimated risks and compromised safety. Here is a step-by-step on-site safety checklist:

Comprehensive Single Line Diagrams (SLDs)

Updated SLDs are the blueprint of your electrical system. They must show connections, configuration, and layout of all components for accurate system modeling. Outdated SLDs cause errors in calculations.

Equipment Specifications

Detailed and accurate data for all electrical equipment, like switchgear and transformers, is crucial. This includes:

Voltage Levels and Equipment Ratings: Needed to determine the size of possible electrical faults.
Interrupting Ratings: Shows the equipment's maximum capacity to safely shut down during a malfunction.
Protective Device Settings: Used to minimize incident energy (heat) and calculate how quickly a fault is cleared.

Without this data, the safety assessment will be inaccurate.

System Operating Conditions

You must understand the system's normal and worst-case operating settings. Document load patterns, seasonal demands, and peak loads. This data helps simulate realistic arc flash scenarios. It reflects everyday risks and ensures NFPA 70E compliance.

Protective Device Coordination and Settings

Protective devices (relays, breakers, fuses) must limit the duration of a fault. Their time-current characteristics determine how fast they trip. Inadequate protection leads to higher incident energy and worse injuries. You should gather:

Time-current curves for all relays and breakers.
Device coordination settings.
Accurate data on these devices enables precise incident energy calculations.

Up-to-Date Short-Circuit Data

Recent short-circuit data is essential, as incident energy (the heat level) depends on fault current magnitude (the amount of electricity flowing during a fault. Short-circuit studies provide crucial fault current values for arc flash calculations. Ensure this data is accurate and current.

Equipment Labeling and Identification

Equipment labels must exactly match the SLDs. Each panel, transformer, and similar equipment needs a unique identifier. This simple step prevents data input errors during the verification and risk assessment process in the field.

PPE Requirements (Based on Incident Energy Levels)

The calculated incident energy level determines the necessary Personal Protective Equipment (PPE). Prepare PPE ratings based on the calculated energy. This information must be shown on safety labels and in the final report.

Equipment Maintenance Records

Regular maintenance affects system safety and reliability. Collect recent maintenance records, inspection reports, and condition monitoring data (such as thermographic scans and insulation resistance tests). Well-maintained systems generally have fewer hazards, making this information critical to a realistic risk assessment.

Fault Clearing Times & Relay Coordination Data

The fault clearing time (how fast the power shuts off) is a major factor in reducing incident energy levels. Accurate relay coordination data shows how quickly faults are cleared, minimizing hazards. Verify relay settings and their coordination across the entire protection system.

10. Utility Short-Circuit Contribution

You must know how much electricity the utility company provides. This is needed to get accurate fault current levels, especially at the main service entrance. Get maximum and minimum fault current data from the utility to ensure realistic system conditions.

Get Your Arc Flash Safety Training Online

The core of an effective arc flash safety system is accurate and comprehensive data collection. With the above checklist, you can conduct a thorough analysis to boost workers' safety and minimize arc flash risks. However, simply following a list or buying PPE is not enough. Your employees must have the knowledge and skills to know exactly what to do.

They must have an arc flash certification course to fully comprehend the importance and implement it effectively. Do you want to improve your safety program? Take our arc flash safety training online course now to discover how to remain safe, secure, and compliant at work.

FAQs

What are the different types of arc flash boundaries?

There are three boundaries: the limited approach and restricted approach boundaries protect against electric shock. The arc flash boundary specifically protects personnel from dangerous heat exposure.

What are the five types of PPE?

Five common types of PPE include head, eye and face, hearing, respiratory, and hand protection. Other essential types include footwear and body protection, depending on the job hazard.

What is the limit on the arc flash boundary?

The arc flash boundary is calculated at 1.2 cal/cm2 of incident energy. This distance is where an unprotected worker would sustain a second-degree burn. The limited approach boundary is sometimes further out.

LearnTastic

Author

LearnTastic

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LearnTastic is a trusted leader in professional certification, offering expertly-designed online courses in OSHA training, physical therapy continuing education, caregiver certification, and more. Our flexible programs help professionals meet regulatory requirements, enhance skills and advance their careers. With a focus on practical, up-to-date learning, we empower professionals to thrive in their industries.

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Arc-Flash Boundaries & PPE Categories: Quick Field Checklist

Table of Contents

What Are Arc Flash Boundaries?

PPE Categories Explained

Four Categories of Arc Flash PPE

Arc Flash Safety: Quick Field Checklist

Comprehensive Single Line Diagrams (SLDs)

Equipment Specifications

System Operating Conditions

Protective Device Coordination and Settings

Up-to-Date Short-Circuit Data

Equipment Labeling and Identification

PPE Requirements (Based on Incident Energy Levels)

Equipment Maintenance Records

Fault Clearing Times & Relay Coordination Data

10. Utility Short-Circuit Contribution

Get Your Arc Flash Safety Training Online

FAQs

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