Arc Flash PPE Selection Guide & Sizing Chart
Select the right arc-rated personal protective equipment for your workers
Protect Your Team with Proper Arc Flash PPE
Arc flash incidents can cause severe injuries or death in a fraction of a second. Selecting the right personal protective equipment based on NFPA 70E requirements is critical for worker safety.
This comprehensive guide covers PPE categories, arc rating requirements, sizing charts, and selection best practices to help you keep your electrical workers safe.
Arc flash PPE selection, HRC vs Category, and how this guide is organized
Arc flash PPE is the layered clothing and gear (arc-rated FR shirts and pants, balaclava or hood, face shield, voltage-rated gloves, dielectric boots) that protects a worker from incident energy released during an arc flash. The arc rating — measured in calories per square centimeter — tells you the maximum incident energy the garment can absorb before second-degree burn risk. Match the PPE arc rating to the calculated incident energy at the working location, with margin.
You may still see the term “HRC” (Hazard/Risk Category). NFPA 70E renamed it to simply “PPE Category” in 2015, but the category numbers (1, 2, 3, 4) still map to the same minimum arc ratings (4, 8, 25, 40 cal/cm²). The four cards below summarize each category and the typical work scope it fits. The PPE sizing charts that follow translate the category into actual SKU dimensions so your purchasing team can place a defensible order.
Need the bigger picture? See the ClarkTE Arc Flash Hub for the IEEE 1584 calculation method, mitigation strategies that reduce PPE requirements (faster relays, arc-resistant gear, remote racking), and the full chain of ClarkTE arc flash services.
NFPA 70E PPE Categories
Category 1
4 cal/cm²Incident Energy Range:
4 - 8 cal/cm²
Required Equipment:
- Arc-rated long-sleeve shirt and pants or arc-rated coverall
- Arc-rated face shield or arc flash suit hood
- Hard hat
- Safety glasses or goggles
- Hearing protection
- Leather work gloves or arc-rated gloves
- Leather work shoes
Category 2
8 cal/cm²Incident Energy Range:
8 - 25 cal/cm²
Required Equipment:
- Arc-rated long-sleeve shirt and pants or arc-rated coverall
- Arc-rated flash suit hood or arc-rated face shield and balaclava
- Hard hat
- Safety glasses or goggles
- Hearing protection
- Leather work gloves or arc-rated gloves
- Leather work shoes
Category 3
25 cal/cm²Incident Energy Range:
25 - 40 cal/cm²
Required Equipment:
- Arc-rated flash suit jacket and pants
- Arc-rated flash suit hood
- Hard hat
- Safety glasses or goggles
- Hearing protection
- Arc-rated gloves
- Leather work shoes
Category 4
40 cal/cm²Incident Energy Range:
40+ cal/cm²
Required Equipment:
- Arc-rated flash suit jacket and pants
- Arc-rated flash suit hood
- Hard hat
- Safety glasses or goggles
- Hearing protection
- Arc-rated gloves
- Leather work shoes
Important: Work Above 40 cal/cm² Prohibited Without Engineering Controls
NFPA 70E prohibits work on energized equipment with incident energy above 40 cal/cm² unless engineering controls (remote operation, arc-resistant equipment, current-limiting devices) reduce the incident energy below 40 cal/cm². Category 4 PPE is the maximum protection available with standard PPE.
PPE Sizing Charts
Arc-Rated Shirts & Coveralls
| Size | Measurement 1 | Measurement 2 | Measurement 3 |
|---|---|---|---|
| Small | 34-36" | 28-30" | 32-33" |
| Medium | 38-40" | 32-34" | 33-34" |
| Large | 42-44" | 36-38" | 34-35" |
| X-Large | 46-48" | 40-42" | 35-36" |
| 2X-Large | 50-52" | 44-46" | 36-37" |
| 3X-Large | 54-56" | 48-50" | 37-38" |
Note: Measurements are approximate. Always try on PPE before purchasing and refer to manufacturer-specific sizing charts.
Arc-Rated Gloves
| Size | Measurement 1 | Measurement 2 | Measurement 3 |
|---|---|---|---|
| Small (7) | Palm: 7.5" | Length: 10" | Wrist: 6" |
| Medium (8) | Palm: 8" | Length: 10.5" | Wrist: 6.5" |
| Large (9) | Palm: 8.5" | Length: 11" | Wrist: 7" |
| X-Large (10) | Palm: 9" | Length: 11.5" | Wrist: 7.5" |
| 2X-Large (11) | Palm: 9.5" | Length: 12" | Wrist: 8" |
Note: Measurements are approximate. Always try on PPE before purchasing and refer to manufacturer-specific sizing charts.
Flash Suit Hoods
| Size | Measurement 1 | Measurement 2 | Measurement 3 |
|---|---|---|---|
| Universal | Head: 21-24" | Viewing: 4" x 8" | Weight: 12-16 oz |
| Universal + | Head: 24-26" | Viewing: 4.5" x 9" | Weight: 16-20 oz |
Note: Measurements are approximate. Always try on PPE before purchasing and refer to manufacturer-specific sizing charts.
PPE Selection Best Practices
Check the Arc Flash Label
Always refer to the arc flash label on equipment for the incident energy level and required PPE category. Never assume lower protection is adequate.
Ensure Proper Fit
Ill-fitting PPE can reduce protection. Arc-rated clothing should be comfortable enough to work in but not too loose. Gaps can allow arc flash exposure.
Layer for Higher Ratings
Arc ratings are additive when layering. A 4 cal/cm² shirt + 8 cal/cm² jacket = 12 cal/cm² total protection. Ensure no gaps between layers.
Consider Comfort & Mobility
Workers are more likely to wear PPE that fits well and allows movement. Test PPE with typical work tasks before large-scale purchase.
Inspect Before Each Use
Check for tears, holes, contamination, or damage. Damaged arc-rated PPE loses its protective capabilities and must be replaced immediately.
Verify Certification
All arc-rated PPE must be tested per ASTM F1506 or F2178. Look for manufacturer labels showing arc rating (ATPV or EBT value in cal/cm²).
Download Complete PPE Selection Guide & Sizing Charts
Get our comprehensive PDF guide with detailed sizing charts, selection flowcharts, and inspection checklists. Perfect for safety managers and electrical supervisors.
Your free guide includes:
- Complete PPE category requirements for all 4 levels
- Detailed sizing charts for shirts, pants, gloves, hoods, and face shields
- PPE selection flowchart based on incident energy
- Pre-use inspection checklist for arc-rated PPE
- Common mistakes to avoid when selecting PPE
- Care and maintenance guidelines to extend PPE life