What Every Engineer Should Know About Preventing Arc Flash Incidents

How Can Labeling Help Prevent and Arc Flash Incident? 

An arc flash incident occurs when electrical current unexpectedly discharges through the air, generating extreme heat, pressure, and light. These events can happen in less than a second and cause severe burns, explosions, or fatalities. Each year, about 30,000 arc flash incidents occur—many the result of human error or missing visual communication.

Unlabeled panels, faded arc flash warning labels, or undefined arc flash boundaries create dangerous blind spots for workers. Without clear identification, even routine maintenance can become life-threatening.

Labeling closes those gaps. Durable, compliant electrical safety labels identify hazards directly on equipment, outlining approach limits and required PPE. Using an industrial printer like the DuraLabel® Kodiak® Max Industrial Sign and Label System, teams can produce standardized labels that clearly define arc flash boundaries and help prevent avoidable incidents.

The National Fire Protection Association (NFPA), a global non-profit organization dedicated to preventing death, injury, property, and economic loss have created the standard on workplaces electrical equipment that requires examination, adjustment, servicing, or maintenance while energized. The DuraLabel Kodiak Max offers an innovative solution that addresses these concerns through effective custom labeling for these 4 arc flash hazard areas: 

A risk assessment is necessary for any task where there is an arc flash hazard. According to NFPA, there are two acceptable approaches.  

• Incident Energy Analysis—Uses the technical details of a piece of equipment and its installation to calculate the expected heat energy 
•  PPE category—A shortcut for common scenarios, includes general recommendations for protective steps.  

These approaches should be documented and reviewed once every five years. Kodiak Max can create custom safety labels for your facility that inform workers of the deadlines for the next review.

2. Keep at a safe distance
Create and document arc flash boundaries using one of NFPA’s acceptable methods. Once the distance has been determined, creating warning labels through custom label printing, determining the required PPE, and training workers should follow. The Kodiak Max label printer can create custom industrial labeling to inform workers about the protection they will need to work on energized equipment. 

3. Wear suitable Personal Protective Equipment (PPE) 

PPE protects the wearer against any physical harm or hazards that the workplace environment may present. NFPA uses four Arc Flash PPE Categories to classify ranges of hazards. Each category includes a minimum Arc Rating (AR) value, determined by the PPE manufacturer, that indicates the amount of heat energy that the clothing can absorb before the wearer is burned. DuraLabel Kodiak Max can create industry compliant labels to inform workers about the protection they will need to work on energized equipment.  

Workers who have not been trained are put at a greater risk of injury. The Hierarchy of Controls can assist with worker safety through a system that puts the most effective protections at the forefront and the least effective at the bottom. This process should be taught and implemented during training and reinforced through signage that can be created using the DuraLabel Kodiak Max printer.  

Arc Flash Labeling Simplified for User 

Navigating the complexities of Arc flash labeling is made significantly more manageable with the aid of arc flash label printers like the DuraLabel Kodiak Max. A full database of arc flash standard hazard symbols simplifies compliance and enhances workplace safety. DuraLabel Kodiak Max industrial label printer can help your business and protect the well-being of employees. 

Resources from DuraLabel to Create a Visual Factory 

For other challenging safety situations, like HazCom labeling, read  DuraLabel’s free Arc Flash labeling Quick Start Guide next as it provides relevant information about PPE requirements, arc flash boundaries, but most importantly compliance standards. The free guide helps readers understand the appropriate regulations and standards and improve safety and efficiency. Request your free copy of the Arc Flash Quick Start Guide. 

It is important that your facility has the resources to keep its workers safe. Get help crafting a labeling system with DuraLabel Toro® Max Sign and Label System and Kodiak Max that will provide the safety communication you need. Call 1-888-788-9936 and one of our experts will guide you through the process.

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