Arc Flash Protection
VISARC & the Importance of Whole-Face Arc Flash Protection
August 6th, 2026
The PENTA VISARC arc flash helmet has been developed to protect one of the most exposed areas of an electrical worker’s body during an arc flash: the face.
Arc flash jackets, trousers, coveralls and switching suits can protect the body, but they do not automatically protect the eyes, forehead, cheeks, jawline, chin or sides of the face.
The VISARC Electrical Safety Helmet addresses this risk by combining an electrically insulating helmet shell, an integrated retractable face shield and, depending on the selected configuration, rigid chin and lateral protection.
This coordinated helmet system is designed to protect electrical workers against arc flash heat, ultraviolet radiation, molten-metal projections, high-speed particles and mechanical hazards while maintaining the visibility needed for detailed electrical work.
Available in APC1, APC2 12 cal/cm² and APC2 25 cal/cm² configurations, VISARC enables head and face protection to be selected according to the electrical risk assessment rather than applying one protection level to every task.
Thorne & Derrick supply the PENTA VISARC Helmet alongside arc flash clothing, insulating gloves and specialist electrical safety equipment for workers operating on or near LV, MV and HV Electrical Systems.
Quick Answer: How Does VISARC Protect the Face During an Arc Flash?
The PENTA VISARC Helmet combines an electrical safety helmet with an integrated arc flash face shield. APC2 configurations also incorporate rigid, retractable chin and lateral protection to extend protective coverage beneath and around the face.
The arc flash helmet is designed to protect against the thermal effects of an electrical arc, ultraviolet radiation, molten-metal projections, high-speed particles and mechanical hazards.
VISARC is available in three configurations: APC1, APC2 with an ATPV of 12 cal/cm² and APC2 with an ATPV of 25 cal/cm². The correct configuration must be selected through a competent electrical risk assessment.
PENTA VISARC Arc Flash Face Protection Helmet
What Is the PENTA VISARC Arc Flash Helmet?
The PENTA VISARC arc flash helmet is an integrated head and face protection system for electrical workers.
It has been designed to address several hazards within one coordinated assembly:
- Thermal hazards from an electrical arc
- Electrical risks affecting the head
- Mechanical impact and penetration hazards
- Ultraviolet radiation
- Molten-metal projections
- High-speed particles
- Reduced visibility caused by fogging, scratches or distortion
Instead of attaching a separate face shield to a general-purpose helmet, VISARC integrates the helmet shell, face shield and protective frame into one system.
This is important because every component of Category III electrical PPE must work together as part of the certified arrangement.
The integrated system also helps protect the face shield when it is retracted into the helmet, reducing its exposure to accidental scratches and damage while it is not in use.
What Can an Arc Flash Do to the Face?
An arc flash is a rapid release of electrical energy through the air between conductors or from an energised conductor to an earthed surface.
The event can occur following insulation breakdown, accidental contact, equipment failure, contamination, loose connections, incorrect operation or the introduction of a conductive object.
An electrical arc may release:
- Intense thermal energy
- Visible and ultraviolet radiation
- Molten and vaporised metal
- High-speed equipment fragments
- Hot gases and smoke
- A powerful pressure wave
- Extremely high noise levels
The face is particularly vulnerable because it may be close to the electrical equipment and is not protected by the garments covering the torso, arms or legs.
Arc flash exposure is not limited to high-voltage systems. Serious electrical arcs can occur on LV equipment as well as MV and HV systems.
The actual risk depends on the equipment, available fault current, protection clearing time, working distance, configuration and task being performed.
Why Is Arc Flash Clothing Not Enough to Protect the Face?
Arc flash clothing only protects the areas it covers.
An arc-rated jacket, pair of trousers or coverall may protect the torso, arms and legs, but those garments do not automatically protect the face.
A complete arc flash PPE system may also require:
- An arc flash helmet
- An arc-rated face shield or visor
- Chin and lateral facial protection
- An arc flash hood or balaclava
- Safety glasses
- Electrical insulating gloves
- Suitable protective overgloves
- Hearing protection
- Appropriate safety footwear
VISARC has been designed specifically to address protection above the neckline.
The integrated helmet and face shield provide protection across the head, eyes and central facial area. The chin and lateral protection available within the VISARC range extends coverage around areas that may remain more exposed with a conventional open-bottom face shield.
How Does VISARC Extend Arc Flash Protection Around the Face?
The design of the PENTA VISARC Helmet considers more than protection directly in front of the eyes.
An electrical arc can occur below, beside or at an angle to the worker. Heat, ultraviolet radiation and projected particles may therefore reach areas outside the centre of a conventional visor.
VISARC addresses this through a combination of:
- An integrated face shield protecting the eyes and central facial area
- A helmet shell protecting the upper head
- Rigid protection beneath the face shield towards the chin
- Lateral extensions around the sides of the face
- Overlap between the protective components
- A retractable design that allows the complete system to remain attached to the helmet
Coloured Helmet Crest Options
For the APC1 version, rigid chin and lateral protection can be specified as an accessory and may be removed where permitted by the approved configuration.
For the APC2 versions, the retractable chin and lateral protection forms part of the helmet’s certified arc flash arrangement.
Whole-face coverage should not be confused with full head-and-neck enclosure. Some higher-risk tasks may require an arc flash hood, balaclava, shroud or complete switching suit.
The correct arrangement must always be determined by the task-specific risk assessment.
How Does the VISARC Arc Flash Face Shield Perform?
The face shield is one of the most important elements of an arc flash helmet.
It must provide the required protective performance while allowing the electrical worker to see equipment, conductors, labels, indicators and test points clearly.
The VISARC face shield is designed to protect against:
- Thermal effects from an electrical arc
- Ultraviolet radiation
- Molten-metal projections
- High-speed particles
- External scratching
- Internal fogging
It provides Optical Class 1 performance, the highest optical classification, helping reduce image distortion, visual blur and eye fatigue.
The internal surface is treated to resist fogging, while the outside of the shield is scratch-resistant.
These characteristics are directly relevant to safe working performance.
A visor that fogs, becomes heavily scratched or distorts the worker’s view can make it more difficult to:
- Identify cable and conductor markings
- Read equipment labels
- See warning indicators
- Position tools accurately
- Recognise damaged equipment
- Maintain awareness of the surrounding work area
Why Are VISARC Chin and Lateral Protection Important?
A conventional face shield primarily protects the area directly in front of the wearer.
During an arc flash, however, the heat, radiation, molten metal and projected particles may not travel in a straight line towards the middle of the shield.
The electrical arc may be:
- Below the worker’s eye level
- To one side of the worker
- Inside partially enclosed equipment
- Reflected or channelled by the equipment enclosure
- Directed around the lower or lateral edge of a visor
VISARC’s rigid chin and lateral protection extends the protected area beneath and around the face shield.
This helps reduce open areas around the jawline and sides of the face while maintaining a retractable system that remains integrated with the helmet.
The design is particularly relevant to electrical tasks involving:
- Switchgear operation
- Circuit-breaker racking
- Electrical testing
- Fault finding
- Cable jointing and termination work
- Maintenance inside electrical panels
- Commissioning and inspection
The chin and lateral protection must remain in the approved position and configuration required for the selected VISARC protection level.
It should not be removed, modified or replaced with an unapproved component.
Arc Flash Protection up to 25Cal with VISARC
VISARC APC1, APC2 12 Cal and APC2 25 Cal Explained
The PENTA VISARC range is available in three principal arc flash protection configurations.
This allows the wearer or duty holder to select the appropriate system using the findings of the electrical risk assessment.
VISARC APC1
The APC1 version provides Class 1 electrical arc protection under the box-test method.
It does not use an ATPV value from an open-arc test and should not be described as a particular cal/cm² helmet unless supported by specific manufacturer certification.
Rigid chin and lateral protection can be added to the APC1 helmet using the approved mounting points. A flame-resistant fabric lateral protection option is also available.
VISARC APC2 – 12 cal/cm²
The 12 cal/cm² version combines APC2 box-test performance with an ATPV of 12 cal/cm².
It includes the integrated retractable chin and lateral protection system, extending the protected area beneath and around the face shield.
VISARC APC2 – 25 cal/cm²
The 25 cal/cm² configuration provides the highest arc rating within the VISARC range.
It combines APC2 box-test classification with an ATPV of 25 cal/cm² and the integrated retractable chin and lateral protection system.
Which Standards Does the PENTA VISARC Helmet Meet?
The standards applying to VISARC depend on whether the component being considered is the helmet shell, face shield or complete helmet-and-shield assembly.
Standards provide evidence of performance under defined test conditions. They do not mean that one helmet configuration is suitable for every electrical installation or task.
The 30kV test level of the helmet shell must not be treated as a general working-voltage recommendation for the complete PPE system.
Electrical PPE selection should be based on the specific hazard, task, system and risk assessment.
Why Do Visibility and Optical Quality Matter During Electrical Work?
Protection is only effective when the worker can wear it correctly throughout the task.
Electrical work can involve small conductors, closely spaced terminals, labels, test points and equipment indicators. Poor visibility can increase the possibility of mistakes.
The VISARC face shield is designed to reduce:
- Image distortion
- Visual blur
- Eye fatigue
- Internal fogging
- Obstruction caused by surface scratches
Its Optical Class 1 performance supports extended use where clear vision is essential.
The face shield also provides a high level of visible light transmission for its protection class, helping the user work without unnecessarily lifting the shield.
A scratched or damaged face shield must still be inspected and replaced where required. Scratch resistance does not make the surface immune to damage.
Why Does the Integrated VISARC Helmet Design Matter?
Arc flash head protection is sometimes assembled from a helmet, separate visor carrier and additional components.
VISARC has instead been developed as a coordinated system.
The integrated design provides several practical benefits:
- The face shield remains attached to the helmet
- The shield can be lowered and retracted as part of the same system
- The helmet structure protects the shield while it is raised
- Chin and lateral protection remain aligned with the face shield
- The certified components are designed to work together
- The system is balanced for prolonged electrical work
- Approved accessories use designated mounting positions
The helmet uses a double-shell design that helps protect the retracted face shield and prolong its usable condition.
This is particularly important because scratches, cracks, chemical contamination or unapproved modifications can affect the performance of an arc flash face shield.
An integrated system also reduces the need to assemble unrelated helmet and visor components on site.
Can VISARC Protection Be Customised for Different Electrical Workers?
VISARC has been designed as a modular helmet platform.
This allows the helmet to be configured around the role, working environment and required level of protection without changing the certified protection level of the selected helmet.
Available options can include:
- Rigid chin and lateral protection for APC1
- Flame-resistant fabric lateral protection
- Integrated headlamp modules
- Personal voltage alarm options
- Neck protection against ultraviolet radiation
- Retroreflective strips
- Approved hearing protection
- Coloured helmet crests for role identification
- Company logo personalisation
Coloured crests can be used to distinguish teams or responsibilities on a shared site, such as different authorised roles or work supervisors.
Integrated electronic modules can combine a headlamp with additional functions, including rear visibility lighting and a personal electric-field alarm.
A personal voltage alarm is an additional warning device. It must not replace:
- Safe isolation
- Approved voltage detection procedures
- Test-before-touch requirements
- Electrical risk assessment
- Site safety rules
Not every accessory combination is compatible. The approved manufacturer configuration must be checked before combining lateral protection, hearing protection, lighting or electronic modules.
How Should a VISARC Arc Flash Helmet Be Selected?
The correct VISARC configuration should be selected using the results of a competent electrical risk assessment.
It should not be selected using voltage alone.
Important factors include:
- The electrical task being performed
- The system voltage
- The available fault current
- The protection clearing time
- The predicted or calculated incident energy
- The equipment type and configuration
- The condition and maintenance history of the equipment
- The working distance
- The position of the worker
- The possibility of a constrained or directed arc
- The clothing and other PPE being worn
- The need for additional neck or hearing protection
A higher arc rating is not automatically the best choice for every task.
The selected helmet should provide adequate protection without unnecessarily reducing visibility, mobility or comfort.
Who May Need a PENTA VISARC Arc Flash Helmet?
VISARC may be considered wherever electrical workers could be exposed to electric arc hazards during operation, testing, inspection, maintenance or fault conditions.
Potential users include:
- Cable jointers
- Authorised and senior authorised persons
- Electrical maintenance technicians
- Switchgear engineers
- Substation engineers
- Utility workers and linesmen
- Industrial electricians
- Rail and traction-power engineers
- Renewable-energy technicians
- Data-centre electrical teams
- Battery energy storage technicians
- Electric-vehicle infrastructure engineers
- Electrical testing and commissioning personnel
VISARC may be used within industries such as:
- Electricity transmission and distribution
- Utilities and substations
- Manufacturing and industrial processing
- Rail infrastructure
- Renewable energy
- Data centres
- Oil, gas and petrochemical facilities
- Marine and offshore installations
- Battery storage
- Commercial power distribution
The industry or job title does not determine the correct helmet. Selection must be based on the actual task and electrical hazard.
Can the PENTA VISARC Helmet Prevent an Arc Flash?
No helmet or item of PPE can prevent the electrical fault itself.
VISARC is designed to reduce the potential severity of injury if an arc flash occurs within the tested limitations of the selected helmet configuration.
Preventing the event and avoiding exposure must remain the priority.
Arc flash risk management should consider:
- Predict – identify the arc hazard and assess its possible severity.
- Prevent – eliminate the hazard or reduce the likelihood and severity of an event.
- Process – implement competent people, safe procedures and controlled working practices.
- Protect – select suitable PPE for any residual risk that remains.
Risk reduction measures may include:
- De-energising and safely isolating equipment
- Remote switching or operation
- Increasing working distance
- Reviewing protection settings
- Using arc-resistant equipment
- Improving equipment maintenance
- Restricting access
- Providing electrical safety training
- Implementing task-specific procedures
- Wearing correctly selected arc-rated PPE
How Should the VISARC Helmet Be Inspected and Maintained?
The VISARC helmet should be inspected before each use.
Checks should include:
- No cracks, splits or visible damage to the helmet shell
- No serious scratches, cracks or damage to the face shield
- No signs of chemical contamination
- The face shield lowers fully
- The face shield clips correctly onto its frame
- The chin and lateral protection moves and locks correctly
- The harness and chinstrap are secure
- Accessories are fitted in accordance with PENTA instructions
- No unapproved modifications have been made
Any helmet that has sustained a significant impact should be replaced, even where damage is not immediately visible.
For cleaning:
- Clean the helmet using lukewarm soapy water or a suitable soft wipe
- Allow the helmet to dry at room temperature
- Use the supplied microfibre cloth to remove dust from the face shield
- Use lukewarm water without soap for more thorough visor cleaning
- Do not use products containing solvents
- Follow the full instructions supplied with the helmet
PENTA states that the helmet can be stored for up to three years from its manufacturing date and used for up to five years from the date of first use, provided that it continues to pass the required pre-use inspections.
Actual replacement may be required earlier if the helmet is damaged, contaminated, modified, subjected to impact or fails inspection.
Common PENTA VISARC and Arc Flash Helmet Mistakes
Incorrect selection or use can create gaps in protection.
Common mistakes include:
- Selecting the helmet using voltage alone – arc flash severity also depends on fault current, clearing time, equipment configuration and working distance.
- Assuming arc flash clothing protects the face – garments only protect the areas they cover.
- Treating an ordinary visor as arc flash protection – general impact or splash protection does not automatically provide certified electrical arc protection.
- Removing APC2 chin protection – the integrated protection is part of the certified APC2 configuration.
- Changing the face shield to alter the protection level – the originally certified VISARC protection level must be maintained.
- Mixing unapproved components – unrelated helmets, shields and accessories may invalidate the certified arrangement.
- Using a damaged or heavily scratched visor – damage can affect visibility and protective performance.
- Ignoring the chin and sides of the face – an electrical arc may occur below or beside the worker.
- Assuming the highest rating suits every task – PPE should be proportionate to the assessed exposure.
- Using the voltage alarm as a voltage detector – a personal alarm does not replace safe isolation or approved voltage testing.
- Failing to inspect the helmet – cracks, impact damage or contaminated components may prevent the helmet performing as intended.
- Assuming PPE prevents the incident – VISARC reduces potential injury but cannot prevent an electrical fault.
Related VISARC and Arc Flash Safety Products
The VISARC helmet should be selected as part of a complete electrical safety PPE system.
- PENTA VISARC Arc Flash Helmet – integrated head and face protection available in APC1, APC2 12 cal/cm² and APC2 25 cal/cm² configurations.
- Arc Flash Helmets and Visors – helmet, face shield and hood options for electrical arc hazards.
- Arc Flash Clothing and PPE – electrical arc protection for the body, head, face and hands.
- Electrical Safety Equipment – safety equipment for LV, MV and HV electrical systems.
- Electrical Head Protection – helmets, face shields, visors and associated head protection.
- Electrical Insulating Gloves – insulating hand protection for electrical workers.
- PENTA ALADIN Personal Voltage Alarm – personal electric-field warning equipment for suitable electrical applications.
PENTA VISARC Arc Flash Helmet FAQs
Q: What is the PENTA VISARC helmet?
A: PENTA VISARC is an integrated electrical safety helmet and arc flash face shield system. It provides electrical and mechanical head protection alongside certified face protection against electrical arc hazards.
Q: Does the VISARC helmet protect the whole face?
A: The integrated face shield protects the eyes and central facial area. Rigid chin and lateral protection extends coverage beneath and around the face. This protection is integrated into APC2 models and available as an approved option for APC1. Some tasks may still require additional neck protection or a complete arc flash hood.
Q: What protection levels are available?
A: VISARC is available in three principal configurations: APC1, APC2 with an ATPV of 12 cal/cm² and APC2 with an ATPV of 25 cal/cm².
Q: What is the difference between VISARC APC1 and APC2?
A: APC1 and APC2 represent different box-test arc protection classes. APC2 involves the more severe test exposure. VISARC APC2 models are also available with ATPV ratings of 12 or 25 cal/cm² and include integrated chin and lateral protection.
Q: Is the APC1 VISARC helmet rated in cal/cm²?
A: No open-arc ATPV rating is stated for the APC1 VISARC configuration. It is classified using the APC1 box-test method and should not be assigned a cal/cm² value without specific manufacturer evidence.
Q: Is a 25 cal VISARC helmet always better than a 12 cal helmet?
A: The 25 cal configuration has a higher tested arc rating, but the correct helmet should be selected according to the assessed incident energy, task, visibility, working conditions and complete PPE system. The highest rating is not automatically required for every application.
Q: Can the VISARC face shield be changed to alter the arc protection level?
A: No. The protection level originally certified and supplied by PENTA must be maintained. Changing Category III PPE components outside the approved configuration may invalidate the certification.
Q: Is the VISARC face shield anti-fog and scratch-resistant?
A: Yes. The face shield has anti-fog treatment on its internal surface and scratch-resistant treatment on its external surface. It should still be inspected before use and replaced if damaged.
Q: What optical class is the VISARC face shield?
A: The VISARC face shield provides Optical Class 1 performance, helping reduce image distortion and visual fatigue during extended use.
Q: Does arc flash clothing protect the face?
A: No. Arc flash garments protect only the areas they cover. A certified arc flash helmet, face shield or hood may be required to protect the head, eyes and face.
Q: Is an ordinary safety visor suitable for arc flash protection?
A: Not necessarily. General impact or splash protection does not automatically provide protection against electrical arc hazards. The visor must have the appropriate arc flash certification and performance for the task.
Q: Can VISARC be used for LV, MV and HV electrical work?
A: VISARC may form part of the PPE used across LV, MV and HV environments, but suitability cannot be decided from voltage alone. The task, system, incident energy, working distance and complete risk assessment must be considered.
Q: Can VISARC include a voltage alarm?
A: VISARC can be configured with an integrated headlamp and personal electric-field alarm. The alarm is an additional warning device and does not replace approved voltage detection, safe isolation or test-before-touch procedures.
Q: How long does a VISARC helmet last?
A: PENTA states a maximum storage period of three years from manufacture and a maximum in-use period of five years from first use, subject to correct storage, maintenance and successful pre-use inspection. Damage or impact may require earlier replacement.
Q: Can the VISARC helmet prevent an arc flash?
A: No. VISARC is designed to reduce potential injury if an arc flash occurs within the helmet’s tested limitations. It cannot prevent the electrical fault. Isolation, risk reduction and safe working procedures remain the priority.
Conclusion: Arc Flash Protection Should Not Stop at the Collar
An arc flash can expose the eyes, skin, chin and sides of the face to intense heat, ultraviolet radiation, molten metal and high-speed particles.
Arc flash clothing can protect the body, but it cannot protect facial areas that remain uncovered.
The PENTA VISARC arc flash helmet has been developed to address this gap through an integrated helmet, retractable face shield and configurable chin and lateral protection system.
Its Optical Class 1 visor, anti-fog and scratch-resistant surfaces, integrated double-shell design and three protection configurations provide a flexible head and face protection platform for electrical workers.
The range includes:
- VISARC APC1
- VISARC APC2 with an ATPV of 12 cal/cm²
- VISARC APC2 with an ATPV of 25 cal/cm²
The correct configuration must always be selected through a competent arc flash risk assessment and worn with suitable clothing, gloves, hearing protection and any additional head or neck protection required for the task.
Thorne & Derrick supply PENTA VISARC helmets, arc flash clothing, face protection, insulating gloves and electrical safety PPE for LV, MV and HV electrical workers operating across utilities, substations, rail, renewables, data centres, industry and power distribution.
Layering Up: Why What’s Underneath Your Arc Flash Kit Really Matters
April 9th, 2026
layering up: why what’s underneath your arc flash kit really matters
When workers think about arc flash PPE, the focus usually lands on the visible outer layer – the coverall, jacket, trousers that carries the certification label and takes the brunt of the hazard. But that is only part of the story.
What sits underneath that outer garment can have a major effect on the overall outcome in the event of an incident. If the wrong underlayer is worn, even good outer protection can be compromised. That is why layering is not simply about comfort or warmth, it is a critical part of the protective system.
For teams working around electrical hazards, choosing Progarm manufactured arc-rated baselayers instead of ordinary everyday clothing can make a meaningful difference to protection, comfort and confidence on site.
the hidden risk of everyday underlayers
A worker may appear fully protected because the outer garment is compliant, correctly fitted and worn properly. However, underneath that outer kit there is often a standard T-shirt, sports layer or thermal garment that was never designed for arc flash exposure.
This is where the problem begins. Everyday clothing is chosen for convenience, not for its behaviour under extreme thermal conditions. In an arc flash event, heat can still transfer through the outer layer. If the garment underneath is not suitable, it can contribute to burn injury rather than help reduce it.
- Standard underlayers are not selected as part of an arc-rated PPE system
- Workforces often mix protective outerwear with everyday clothing underneath
- This creates inconsistency from one worker to another
- It can weaken the effectiveness of the overall clothing solution
That is why layering should be treated as a deliberate safety decision, not a personal clothing preference.
why arc-rated baselayers are different
Arc-rated baselayers are designed specifically to sit close to the skin as part of a layered protective system. Their purpose is not simply to add warmth. They are chosen to support the overall garment performance while helping the wearer remain comfortable throughout the working day.
A good baselayer strategy helps create a more complete barrier between the wearer and the hazard. It also gives specifiers and safety managers greater control over what staff are actually wearing beneath certified outer garments.
For organisations trying to standardise PPE across multiple teams, baselayers offer a practical way to reduce guesswork and improve consistency.
protection starts from the skin outwards
One of the most important ideas in arc flash clothing selection is that protection should be built from the inside out. The outer garment may be the first thing seen, but the inner layer is the closest to the body and therefore directly relevant to comfort and injury reduction.
This is particularly important in environments where workers need to wear PPE for long periods, move between indoor and outdoor tasks, or manage variable temperatures through the day. In those situations, baselayers can support both wearability and compliance by making it easier to dress correctly without improvising with unsuitable clothing.
If a PPE system is uncomfortable, workers are more likely to adapt it. If the system is wearable, breathable and clearly specified, compliance usually improves.
layering is not just for winter
It is easy to assume that baselayers are only useful in cold conditions, but that is too narrow a view. In electrical safety clothing, layering is primarily about system performance, not just insulation against the weather.
A well-planned baselayer approach can be relevant year-round because it supports:
- consistent protection across shifts and seasons
- better garment management and standardisation
- reduced reliance on ad hoc personal clothing choices
- improved comfort where breathable PPE is required for long hours
In other words, the right baselayer is not an optional extra. It is part of making the outer garment work as intended.
certifications and standards that matter
When specifying an arc flash clothing system, certification matters because it provides a framework for comparing garments against recognised requirements. Depending on the job, sector and wider hazard profile, several standards may be relevant.
The exact combination of standards required will depend on the application, but the key point is that a compliant outer garment should be supported by a compatible layering approach rather than undermined by unsuitable clothing underneath.
what a good layering policy looks like
For employers, the challenge is not only choosing good garments, but making sure the full clothing system is easy to understand and easy to follow. A practical layering policy should remove ambiguity and make the correct choice the obvious choice.
- Specify approved arc-rated baselayers as part of the PPE issue
- Explain why everyday underlayers are not acceptable
- Match clothing choices to the task risk assessment
- Consider comfort and wearability to support real-world compliance
- Train teams to view PPE as a complete system, not separate items
This approach helps bridge the gap between product certification and how garments are actually worn in the field.
from compliance to real-world protection
There is a difference between owning compliant PPE and achieving effective protection in practice. Real-world safety depends on how garments are combined, worn and maintained.
That is why baselayers deserve more attention in procurement and safety planning. They are not the most visible part of the kit, but they are one of the easiest ways to strengthen the integrity of the full clothing system.
For safety professionals, contractors and electrical teams, the message is clear: arc flash protection is not only about the outer shell. The right underlayers matter too.
Shaping the Future of Arc Flash Safety: ProGARM x GORE-TEX Brand Partnership
February 13th, 2025
GORE-TEX PYRAD | Arc Flash Clothing
Thorne & Derrick | Arc Flash Protection Clothing Distributed from Stock | Approved Supplier | UK & Export Sales
Arc Flash Clothing
GORTEX PYRAD
When two industry giants unite, extraordinary things happen. When that union is centred around human safety, lives are saved. ProGARM and the GORE-TEX Brand have recently launched a new range of next-generation arc-rated GORE-TEX PYRAD® stretch product technology workwear, marking a new era of innovation in protective garments.
Arc flash and fire resistance garment specialists ProGARM have teamed up with fabric pioneers at W.L Gore & Associates to develop a ground-breaking waterproof and arc-rated GORE-TEX product range. Guided by the principle of ‘safety through comfort,’ this new collection is designed to provide unparalleled protection while ensuring exceptional wearability. This collaboration is focused on delivering the most advanced protective features for workers who rely on high-performance personal protective equipment (PPE) to stay safe on the job.
Thorne & Derrick together with ProGARM are now able to offer the GORTEX PYRAD range of arc flash clothing delivering the ultimate arc flash protection with a wide range of men’s and women’s garments available in hi – vis yellow, hi-vis orange, two-tone yellow, blue and single colour blue.
Arc Flash Safety
Building On A Common Commitment To Safety & Quality
This professional partnership arose from the necessity to reinvent personal protective equipment (PPE) for employees who risk their lives on a daily basis while doing their vital tasks. With decades of expertise in innovative manufacturing and design techniques to deliver safe, compliant and wearable arc flash rated garments, ProGARM is leading the way in delivering fresh thinking in garment technology.
The GORE-TEX Brand, known for its fabrics and technologies that deliver long-lasting functionality and high quality, is the perfect partner, bringing its understanding of fabric technology and industry compliance to be part of something revolutionary.
This partnership is a seamless continuation of the established relationship between the two brands, following the signing of the licensee agreement in 2022. ProGARM is one of only three licensed PPE partners in the UK to utilise Gore’s cutting-edge PYRAD® technology. This highly sought-after collaboration provides a solid foundation of excellence for the companies to build upon with the introduction of their new and innovative product range.
Innovation | GORTEX PYRAD
Breakthroughs, Not Just Enhancements
The PPE industry has experienced continuous product evolution, with gradual improvements made to enhance various aspects of arc flash and fire-resistant clothing. Both ProGARM and the GORE-TEX Brand are recognised for their technical expertise, clearly showcasing their deep understanding of garment composition and fabric design to create clothing that delivers outstanding levels of protection.
But now is the time to raise the bar yet again for arc flash safety wear.
The ProGARM x GORE-TEX Brand collaboration is bringing to market a new, exclusive set of waterproof workwear products and it’s thanks to the power of stretch. Understanding the struggles of workwear that doesn’t move with its wearer, this new arc rated GORE-TEX PYRAD® stretch product technology is changing the game.
Not only are the garments technically compliant with all required regulations for arc flash risk environments, but they are super lightweight, breathable and stretchy, even when wet, offering the ultimate combination of protection and comfort in all weathers and environments. The fabric composition is unique, placing stretch technology at the heart of the design for increased wearability with no compromise on arc rated protection.
The Next Generation Of Arc Flash
Triple Layer Protection
Introducing triple-layer technology to the market, the fabric in the new garments offers heat, flame, and arc flash protection by blocking heat flow and preventing flame propagation, thereby stopping heat from reaching the wearer’s skin. The new range of jackets, trousers, and coveralls will soon provide workers with the most advanced workwear, delivering unmatched levels of movement, flexibility, and comfort.
Known for designing garments for a range of body shapes and sizes to achieve the best possible fit, ProGARM has brought its extensive knowledge of designing for real bodies to ensure its new range is accessible to all.
The new range will be available in high visibility yellow and navy, and orange to ensure worker visibility is not compromised when on-site, and every aspect of the design is arc flash and flame resistant, right down to the stitching thread for total performance reassurance. Advanced porous technology means the fabric is breathable, working with the overall design of the range to avoid a build-up of heat and perspiration in all weather conditions. This range is designed to be worn, with every design decision made in the boots of the wearer.
With this innovative range of workwear embedded in science, there are GORE-TEX garments to suit the needs of every industry where protection from the devastating risks of an arc flash incident is a priority.
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Award Winning Arc Flash Clothing from ProGARM
February 12th, 2025
Arc 4 Rated Switch Suit
Wins Prestigious Industry Award
Thorne & Derrick is proud to announce that the Arc 4 Rated Switch Suit, developed by ProGARM a leading manufacturer of arc flash clothing, using the cutting-edge PYRAD® Technology by GORE-TEX LABS, has recently won the prestigious Fibre, Fabric & Materials Award at the Professional Clothing Industry Association Worldwide Ltd Awards 2024 (PCIAW®). This recognition highlights innovations that push the boundaries of performance, protection, functionality, and comfort in professional clothing.
The Arc 4 Switch Suit sets a new standard for safety and comfort in Arc Protection.
Thanks to PYRAD® Technology by GORE-TEX LABS, the switching suit delivers Class 2 Arc Flash Protection in a single-ply textile, offering superior safety without sacrificing freedom of movement. Unlike traditional multi-layer, bulky fabrics that can be heavy and restrictive, this thin, lightweight design ensures maximum protection against arc flash incidents without compromising on comfort.
This ground-breaking product is a testament to the power of collaboration, combining ProGARM’s expert craftsmanship with the innovative GORE-TEX LABS technology to deliver a truly exceptional product to market.
The Arc 4 Switch Suit is now setting a new benchmark in the world of professional arc flash protective clothing. Stay tuned for more updates as we continue to push the boundaries of innovation in this field.
Further Reading
- Shaping the Future of Arc Flash Safety: ProGARM x GORE-TEX Brand Partnership
- New Levels of Waterproof Arc Flash Protection I ProGARM & GORE-TEX PYRAD
- Protecting Jointers & SAP’s Against Arc Flash Risks | ProGARM 6444 Coveralls
- ProGARM 4690 Coveralls | Arc Flash Protection for Rail Trackside & Substation
- The First Sustainable Arc Flash Range Of PPE From ProGARM
Unlocking New Levels of Waterproof Arc Flash Protection I ProGARM Partner With GORE-TEX PYRAD
July 23rd, 2024
Thorne & Derrick | Arc Flash Protection Clothing Distributed from Stock | Approved Supplier | UK & Export Sales
GORE-TEX PYRAD STRETCH | ARC FLASH CLOTHING
Thorne & Derrick are a UK Specialist Distributor for ProGARM the arc flash clothing and accessories manufacturer, delivering the ultimate arc flash protection with a wide range of men’s and women’s garments available in hi – vis yellow, hi-vis orange, two-tone yellow, blue and single colour blue.
ProGARM provide practical and functional clothing designed to protect people and save lives with most garments available from stock.
With everything from FR base layers to arc flash waterproofs ProGARM have a complete range of arc rated clothing including polo shirts, sweatshirts, trousers, jackets, softshells and coveralls as well as helmets, gloves and other accessories.
GORE-TEX PYRAD WATERPROOF ARC FLASH CLOTHING
Introducing the most advances Arc Flash Protection combined with levels of wearability, the ProGARM x the GORE-TEX Brand collection has brought the new arc flash clothing line the GORE-TEX PYRAD clothing line.
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Hoods This range of GORE-TEX PYRAD Waterproof Arc Flash Protection is Class 2 rated, Arc Flash and Fire resistant and brings a level of comfort and protection where workers can focus on the job at hand and work for long periods of time outdoors and in tough conditions.
Reaching temperatures of up to 35,000°F—four times hotter than the surface of the sun and producing a sound louder than a gunshot, an arc flash is a terrifying danger that any workplace can be exposed to every day.
Add in the effects of wet weather and other extreme conditions that can impair workers’ ability to perform, and the risk of a life-threatening arc flash incident is heightened.
ProGARM and GORE have joined together to bring the Arc flash protection line to keep wearers warm, dry, and safe.
Arc Rated GORE-TEX PYRAD fabric stays lightweight and comfortable even when wet. They remain up to 20% lighter when wet or dry than other arc protection category 3 garments, making them feel less bulky to wear. Wearing the right protective gear in foul weather can make all the difference in job performance.
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Fabric that avoids a build-up of heat
GORE-TEX fabrics feature durable waterproof and windproof protection with high breathability. The fabric is engineered so that sweat vapour can escape to avoid a build-up of heat and perspiration, and it can also easily withstand high water pressure.
Unlike any other arc flash PPE using the same fabric,
As the only UK manufacturer specialising 100% in arc flash and flame resistant PPE, ProGARM continuously invests in industry-leading research and testing to keep on top of developments in new manufacturing and design techniques, better fabrics, and safer materials.
Pioneering design and attention to detail mean ProGARM’s arc flash PPE is engineered with unique differences to maximise safety and comfort.
Every single element is arc flash and flame resistant, right down to the stitching threads and increasing safety through layers.
Garments are designed to be as comfortable and practical to wear as possible, regardless of gender. ProGARM has developed one of the widest ranges of female-specific arc flash garments on the market, tailoring for different body proportions and for smaller details such as the wider range of motion of female joints—something ProGARM will continue with their new GORE range, which will include jackets, trousers, and coveralls.
Maximising safety and comfort
Maximum comfort with the higher protection from arc flash, so workers remain safe no matter the challenge, or the weather.
Safely fitting workwear for male and female body shapes. High levels of customer service customers have come to depend on. These are just some of the benefits companies and workers can expect to see as ProGARM and GORE unlock new levels of protection in their new range of arc flash PPE.
💡 Did you know? – While high voltage equipment does increase the likelihood and intensity of arc flash explosions, they can occur in any live electrical environment – even low voltage.
Further Reading
- Protection Against Arc Flash, Faults & Electric Shock | 5 Safety Rules
- Arc Flash Clothing Saves Lives | Watch Eddies Story
Arc Flash Learning & Resources
