Arc Flash Safety: A Workplace Electrical Risk Business Owners Can’t Ignore
Most business owners think of electrical hazards as a construction problem. The reality is that any workplace with electrical panels, industrial equipment, or high-voltage systems carries some level of arc flash risk. Between five and ten OSHA-reportable arc flash incidents happen across the country every single day. For employers, that statistic carries real consequences, for their employees and for their business.
What Is an Arc Flash?
An arc flash occurs when electrical energy is released through the air between two conductors, similar to a short circuit, but through open air rather than wiring. Any electrical system operating above 450 volts has the potential for an arc flash event. The National Institute for Occupational Safety and Health (NIOSH) identifies the electric arc as the hottest known event on earth outside of a laser, with temperatures reaching up to 35,000°F.
The injuries that result are not from electric shock. They come from electromagnetic radiation, capable of causing everything from mild skin burns to complete tissue destruction, along with pressure and sound waves that can cause traumatic hearing loss or blunt force injury from flying debris.
The average arc flash victim, according to NIOSH, is 37 years old with 16 years of experience in electrical work. This hazard does not discriminate based on experience level. Common causes include dropped tools, insulation failures, dust or corrosion buildup on equipment, and working too close to a high-current source.
What Does OSHA Require Employers to Do?
Under 29 CFR Part 1910, Subpart S, OSHA requires employers to implement safe work practices to prevent electrical injuries, including those caused by arc flashes. Key obligations include:
Lockout/tagout procedures. All electrical equipment must be de-energized before service or maintenance begins. Exceptions are permitted only when de-energizing is physically impossible or creates a greater hazard, not simply because it’s inconvenient.
Insulated tools and equipment when live circuit work is unavoidable.
Appropriate personal protective equipment (PPE) including face and eye protection, rated for the specific energy level present during the task.
OSHA also recommends following NFPA 70E, a standard from the National Fire Protection Association that provides specific procedures for flash-hazard analysis, equipment labeling, and flame-resistant clothing. While NFPA 70E is not a law, OSHA field inspectors use it as a reference when evaluating compliance, and documented adherence to it can protect businesses from citations under OSHA’s General Duty Clause.
How Does Workplace Electrical Risk Connect to Your Business Insurance?
Burn injuries from arc flash incidents tend to generate more lost workdays than most other workplace injuries. More lost time means higher workers’ compensation claims and over time, that affects what your business pays for coverage.
A NIOSH study found that 94 percent of arc flash events were considered preventable by those who witnessed or experienced them. Building a culture of electrical safety, through proper training, PPE compliance, and OSHA-aligned procedures reduces injury risk and helps control long-term insurance costs.
For business owners across Delaware, Pennsylvania, and New Jersey, this is an area where the right insurance guidance matters. Workers’ compensation and general liability coverage need to reflect the actual risks present in your workplace. As an independent insurance agency, McHugh Insurance Group works with businesses of all types to make sure their coverage keeps pace with their operations.
Want to make sure your business is properly protected against workplace injuries and liability? Reach out to McHugh Insurance Group to review your workers’ compensation and liability coverage.
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