this type of burn results from high temperatures caused by an electric arc or explosion near the body.: Understanding Arc Flash Burns

If you’ve heard the phrase “this type of burn results from high temperatures caused by an electric arc or explosion near the body,” you’re already brushing up against one of the most dangerous hazards in electrical work: arc flash burns. I’ve spent years consulting with industrial teams and safety managers on electrical safety programs, and I’ve seen firsthand how quickly an arc event can change lives. In this guide, I’ll explain what arc flash burns are, why they happen, how to respond, and—most importantly—how to prevent them. Let’s dive in with practical, evidence-backed insights you can use today.

What Is An Arc Flash Burn?

An arc flash burn is a thermal injury caused by an electrical arc that generates extremely high temperatures, intense light, and a pressure wave. Unlike a typical electrical shock, which travels through the body, an arc flash usually causes external burns due to the radiant heat and molten metal propelled by the blast. Temperatures in an arc can exceed 35,000°F, hot enough to vaporize metal and ignite clothing from several feet away.

Key characteristics of arc flash burns:

• Caused by high-temperature plasma from an electric arc
• Often accompanied by blast pressure, flying debris, and intense UV and infrared radiation
• Can occur without direct contact with energized parts
• Frequently involves multiple injury types: thermal burns, shrapnel wounds, and ear or eye injuries

This type of burn results from high temperatures caused by an electric arc or explosion near the body, making it uniquely severe and often catastrophic without proper controls and PPE.

How Arc Flashes Happen: Causes And Risk Factors

Arc flashes are usually triggered by conditions that allow current to leave its intended path and jump through the air. Common causes include:
– Equipment failure due to aging, poor maintenance, or contamination
– Tool slips or accidental contact with energized components
– Loose connections, corrosion, or tracking across insulation
– Dust, moisture, and conductive particles inside switchgear
– Human error during racking, testing, or troubleshooting
– Inadequate lockout/tagout and poor risk assessment

High-risk environments:

• Industrial plants with high-energy electrical systems
• Construction sites using temporary power
• Data centers and facilities with dense electrical distribution
• Mining and utilities where heavy equipment is frequently serviced

Standards like NFPA 70E and OSHA electrical safety rules emphasize the hierarchy of risk controls: eliminate the hazard, substitute safer methods, engineer out risks, implement administrative controls, and use PPE as the last line of defense.

Recognizing Arc Flash Burn Severity: Symptoms And Degrees

Arc flash burns range from superficial to life-threatening. Understanding severity helps guide response:

• First-degree burns: Redness, pain, no blisters. Often from radiant heat exposure at greater distances.
• Second-degree burns: Blisters, severe pain, swelling, possible fluid loss. Common in near-miss arc events.
• Third-degree burns: Charred or leathery skin, possible numbness due to nerve damage. Frequently caused by direct exposure, molten metal, or clothing ignition.
• Additional injuries: Eye damage from UV light, hearing loss from the pressure wave, inhalation injuries from smoke and vaporized metals, fractures or concussions from the blast.

Immediate medical evaluation is crucial for moderate to severe burns, facial or hand involvement, suspected inhalation injury, or any burn larger than the size of your palm.

Immediate First Aid: What To Do And What To Avoid

What to do:
– Ensure scene safety first. De-energize power if possible and safe to do so.
– Call emergency services for suspected moderate or severe burns.
– Cool the burn with cool running water for 10 to 20 minutes. Do not use ice.
– Remove smoldering clothing and jewelry if not stuck to the skin.
– Cover with a clean, dry, non-fluffy dressing to reduce infection risk.
– Monitor for shock: pale, clammy skin, rapid pulse, confusion. Keep the person warm and calm.

What to avoid:

• Do not apply ointments, oils, butter, or adhesive dressings on severe burns.
• Do not pop blisters.
• Do not attempt to remove stuck clothing.
• Do not delay professional care; arc flash injuries can worsen rapidly.

If an electrical shock is suspected in addition to the burn, check responsiveness and breathing and be ready to start CPR if trained and necessary once the scene is safe.

Treatment, Recovery, And Long-Term Considerations

Medical care depends on severity and may include:
– Debridement and sterile dressings for partial-thickness burns
– IV fluids for larger burns to manage shock and fluid loss
– Pain management and antibiotics if infection risk is high
– Skin grafts for full-thickness burns
– Eye and ear exams for UV exposure and blast injuries
– Psychological support; serious arc incidents can lead to anxiety or PTSD

Recovery timelines vary widely. Early rehabilitation, wound care education, and return-to-work planning are essential. Many organizations use incident investigations and post-incident reviews to improve safety controls and training.

Prevention: Controls, PPE, And Smart Work Practices

Strong prevention blends engineering controls, procedures, and PPE. Practical steps include:
– Conduct arc flash risk assessments and label equipment with incident energy levels
– Keep equipment maintained: tighten connections, clean contamination, update insulation
– Use remote racking and switching when possible
– Apply lockout/tagout and verify absence of voltage with rated test equipment
– Establish arc flash boundaries and restrict access during energized work
– Train workers on hazard recognition, emergency response, and PPE use

PPE is the last line of defense:

• Arc-rated clothing and layering appropriate to calculated incident energy
• Voltage-rated gloves and leather protectors
• Arc-rated face shields or hoods with appropriate ATPV rating
• Hearing protection, safety glasses, and hard hats with arc-rated accessories
• Leather or arc-rated footwear

A culture of stop-work authority is vital. If conditions feel wrong, pause and reassess. Data from industry and safety regulators consistently shows that strong procedures and training dramatically reduce arc flash injuries.

Personal Insights: What I’ve Learned On The Job

Across audits and incident reviews, a few lessons keep repeating:
– Cleanliness matters. A dusty MCC room once doubled as storage triggered tracking that led to a small arc event. Simple housekeeping could have prevented it.
– Rushing is the enemy. Most near misses I’ve investigated involved schedule pressure. A five-minute pause to confirm isolation would have avoided almost all of them.
– Dress for the worst credible case. One technician avoided severe facial burns because he wore an arc-rated hood despite colleagues saying “it’s just a quick check.”
– Verify, then trust. Absence-of-voltage testing with a properly rated meter, after lockout/tagout, is non-negotiable.
– Debriefs save lives. After a minor arc incident, the team changed their racking procedure and invested in remote operators. No repeats since.

These aren’t just rules; they’re habits that become second nature and keep people safe.

Common Myths And The Facts

– Myth: Only high-voltage systems cause arc flash. Fact: Low-voltage systems with high available fault current can and do produce severe arc flash.
– Myth: Cotton clothing is enough. Fact: Non-arc-rated fabrics can ignite and continue to burn; wear arc-rated PPE matched to incident energy.
– Myth: I’ll see the danger coming. Fact: Arc flash is instantaneous; prevention and PPE are critical.
– Myth: If I’m not touching it, I’m safe. Fact: Radiant heat and blast travel; boundaries exist for a reason.
– Myth: PPE replaces safe work practices. Fact: PPE is the last resort; controls and procedures come first.

Frequently Asked Questions Of this type of burn results from high temperatures caused by an electric arc or explosion near the body.

What exactly is an arc flash burn?

It’s a thermal burn caused by the extreme heat from an electrical arc, often accompanied by blast pressure and molten metal. It is not the same as an electrical shock, which passes current through the body.

How hot is an arc flash?

Temperatures can exceed 35,000°F, far hotter than the surface of the sun, producing enough radiant heat to cause severe burns several feet away.

What first aid should I give for an arc flash burn?

Ensure the area is safe, call emergency services, cool the burn with cool running water for 10 to 20 minutes, remove jewelry and loose clothing not stuck to the skin, cover with a clean dry dressing, and monitor for shock.

Which PPE protects against arc flash?

Arc-rated clothing and hoods, voltage-rated gloves with leather protectors, face shields, safety glasses, hearing protection, and proper footwear. PPE levels should match the calculated incident energy or category per recognized standards.

Can arc flash happen at low voltage?

Yes. Systems at 208–480 V with high available fault current and certain protective device settings can produce dangerous arc flashes.

What standards guide arc flash safety?

Organizations commonly follow NFPA 70E for electrical safety in the workplace alongside OSHA regulations, utility standards, and manufacturer instructions.

How do I know the right PPE level?

Use results from an arc flash risk assessment and equipment labels to select arc-rated PPE with an ATPV above the calculated incident energy for the task and location.

Conclusion

Arc flash burns are among the most severe injuries in electrical work because this type of burn results from high temperatures caused by an electric arc or explosion near the body. The best defense is a strong safety program: thorough risk assessments, disciplined procedures, reliable maintenance, and correctly selected PPE. Start small if you must—review labels, refresh training, and clean up your electrical rooms. Build habits that make safe choices automatic. If this guide helped, subscribe for more practical safety insights, share it with your team, or leave a question in the comments.