Arc Flash Protection
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.
Electrical PPE Products | Gloves | Arc Flash Clothing | Arc Suits | Coveralls | Helmets & Visors
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
ARC FLASH AWARENESS DAY 7 JUNE 2024 #AFAD24
April 29th, 2024
Special thanks to David Davenport for the kind permission to help promote #AFAD2024
ARC FLASH AWARENESS DAY
7th June 2024
Arc Flash Awareness Day is a focal point for everyone involved with work where arc flash is a risk. The day has been created to drive awareness of the risks of arc flash incidents, and to share best practice on how to avoid and mitigate those risks.
A wide range of partners have chosen to support Arc Flash Awareness Day and Thorne & Derrick International are delighted to help support the inaugural event.
We’re all committed to spreading the safety message and to making sure that everyone comes home safely.
To join the organisations supporting Arc Flash Awareness Day, get in touch.
UPCOMING EVENTS
Join us for the first-ever Arc Flash Awareness Day (AFAD) this summer to:
⚡ Prevent arc flash injuries
🤕 Promote safer workplaces
💪 Save lives
The day will focus on educating and applying best practices to raise awareness broadly among sectors at risk of arc flash incidents – from board-level executives with a responsibility to keep their people safe, to people on the frontline doing jobs directly at risk.
Join in the conversation online using #AFAD24 #arcflashawarenessday24 and follow:
X (formally Twitter)
Facebook
Instagram
LinkedIn
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ARC FLASH AWARENESS APRIL 30, 2024 An illustration of Arc Flash occurrences, how, why and what causes them, the life and career-changing injuries, fatalities and the catastrophic damage an Arc Flash creates. The responsibilities of stakeholders and engineers and the devastating legal consequences. Tue, 30 April 12:45-13.15 BST The Health & Safety Event, NEC Birmingham
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WHAT IS AN ARC FLASH? JUNE 7, 2024 An overview of what an Arc Flash is, how it occurs, indications & what to be aware of; simple measures to prevent. Presented by David Davenport. Fri, 07 Jun 10:00 BST Online
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PREVENTION IS BETTER THAN CURE JUNE 7, 2024 Partial Discharge Monitoring, a simple way of detecting and preventing potential Arc Flash before it occurs. Fri, 07 Jun 11:00 BST Online
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ARC FLASH STUDIES AND ASSESSMENTS JUNE 7, 2024 Do you know how to undertake an Arc Flash study and assess the risks? Emad Hamadi takes us through this process. Fri, 07 Jun 11:45 BST Online
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ARC FLASH PROTECTION, IS IT ALL THAT? JUNE 7, 2024
The certainty of protecting your workers AND your equipment in the event of an Arc Flash. Fri, 07 Jun 12.30 BST Online
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ON-SITE PROCEDURES TO ENSURE SAFE WORKING JUNE 7, 2024 It’s important that everyone working in an Arc Flash environment understands the On-site Procedures so that they can work safely and not put themselves or colleagues at risk. Fri, 07 Jun 13.15 BST Online
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ARC RATED PPE – THE LAST LINE OF DEFENCE JUNE 7, 2024
Although we can take steps to reduce the likelihood and severity of an Arc Flash, it cannot never be ruled out. Understand the protection you need in the event of an Arc Flash explosion. Fri, 07 Jun 14:00 BST Online
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Arc Flash Awareness Day Information Pack
The official information pack that contains all the information you need about Arc Flash Awareness Day and how you can get involved.
To keep up to date please sign up to the newsletter HERE.
