How to Properly Don and Doff an Arc Flash Suit

Arc flash incidents are some of the most dangerous risks in electrical work. One mistake can mean severe burns, permanent injuries, or worse. PPE is the last line of defense, but if it’s worn incorrectly, it won’t do its job when it matters most.

Too often, workers rush through the process, overlook small but critical details, or assume suiting up is just routine. That’s when dangerous gaps in protection occur. A loose glove, an unsealed closure, or an improperly fitted hood can turn a life-saving suit into false security.

This guide walks you through the right way to don (put on) and doff (remove) an arc flash suit, step by step, so you can ensure maximum protection, full compliance, and peace of mind.

What Is an Arc Flash Suit?

An arc flash suit is a full-body protective system designed to shield workers from electrical hazards. These suits help prevent burns, hearing damage, and other serious injuries caused by intense heat, pressure, and flying debris from an Arc Flash.

Components of an Arc Flash Suit

• Bib-overalls: Protects the legs and lower torso.
• Jacket: Covers the upper body and arms.
• Hood: Includes a face shield and built-in hard hat for head and face protection.
• Rubber Voltage Gloves: Provide insulation from shock hazards.

Protecting employees from arc flash hazards requires more than just providing PPE. It starts with a thorough arc flash assessment of all equipment and electrical systems in the facility, followed by identifying the appropriate level of protection and equipping workers with PPE that meets NFPA 70E and OSHA 1910.269 standards. But protection doesn’t end there. Proper wear matters just as much as the gear itself. Every piece of an arc flash suit must be worn correctly every time maintenance is performed to ensure full protection.

How to Properly Don an Arc Flash Suit

A suit that isn’t put on properly can leave critical gaps in protection, putting workers at risk. With that in mind, let’s go step by step through the correct way to put one on to ensure full protection.

Step 1: Preparation

1. Inspect all gear – Check for tears, burns, or damage. Even minor wear can compromise protection.
2. Ensure PPE is dry – Moisture can increase conductivity and put workers at greater risk.
3. Gather additional PPE – This includes gloves, safety glasses, and hearing protection.

Step 2: Putting on the Bib-Overalls

1. Step into the pant legs carefully, ensuring your boots slide through without excessive force.
2. Fasten the suspender buckles for a secure fit.
3. Adjust the suspenders so they’re snug but not restrictive.

Step 3: Putting on the Jacket

1. Slip your arms into the sleeves and pull the coat over the bib-overalls.
2. Zip the jacket completely and secure all fasteners.
3. Ensure the collar is completely closed and fastened.

Step 4: Donning Additional PPE

1. Put on safety glasses for additional protect against flying debris.
2. Wear hearing protection, such as earplugs, if required.

Step 5: Putting on the Hood

1. Check the hard hat suspension and adjust it for a secure fit.
2. Position the hood over your head, ensuring it fully covers your face and neck.

Step 6: Putting on Gloves

1. Inspect and air-test the gloves before use.
2. Wear the rubber insulating gloves first, followed by leather protectors to protect the rubber gloves from abrasion when in use.
3. Ensure jacket cuffs are fully inside the gloves to prevent exposure.

Final Check

• Confirm that all zippers, straps, and closures are secure.
• Ensure the hood lies flat over the coat, not tucked inside.
• Check mobility, your suit should be snug but allow for movement.

Wearing an arc flash suit correctly is only half the equation, removing and storing it properly is just as important.

How to Properly Doff an Arc Flash Suit

Taking off an arc flash suit might seem simple, but rushing through the process or skipping key steps can put workers at risk. Here’s how to do it safely and protect both the worker and the gear.

Step 1: Removing the Hood

1. Turn off any ventilation system (if applicable).
2. Lift the hood off your head carefully to avoid contaminating the inside.
3. Follow the manufacturer's care instructions for proper cleaning and maintenance
4. Set it down on a clean surface with the opening facing up to dry.

Step 2: Removing the Coat

1. Unzip the front closure and loosen all fasteners.
2. Remove the coat by pulling it off the shoulders and arms.
3. Fold it lengthwise and place it in the storage bag.

Step 3: Removing the Bib-Overalls

1. Unzip the sides and ankles. 
2. Use a wall or chair for balance while stepping out of the legs.
3. Point toes downward as boots slide through the openings.
4. Fold the bib-overalls and place them on top of the coat inside the storage bag.

Step 4: Proper PPE Storage

1. Fold the lower flap of the hood over the face shield to prevent scratches.
2. Tuck the back of the hood inside the hard hat before placing it in the bag.
3. Store the bag in a dry, safe location. For added protection, consider premium storage options with a padded interior and waterproof coating to keep your gear in top condition.

Even when workers follow proper donning and doffing procedures, small mistakes can still compromise safety.

Common Mistakes to Avoid

Many PPE failures aren’t caused by faulty equipment but by human error.  These are a few of the most common mistakes workers make when donning and doffing arc flash suites and how to prevent them.

• Wearing an improperly sized suit: A loose fit can create exposure gaps, while a tight fit can restrict movement.
• Skipping the inspection step: Damaged PPE won’t provide full protection.
• Forgetting to secure gloves over coat cuffs: This leaves wrists exposed to hazards.
• Improperly storing PPE: Damp or contaminated storage conditions can degrade materials.

While proper training can help eliminate many of these issues, the quality of the PPE itself plays a major role in safety. If workers are struggling with uncomfortable, outdated gear, even the best safety practices won’t be enough.

The Right Arc Flash PPE: Comfort, Protection, and Compliance

Not all arc flash suits are built the same. At Enespro, we believe safety should never come at the cost of comfort. That’s why we design arc flash PPE that workers actually want to wear. By using lightweight, breathable materials, our gear reduces heat stress and fatigue, all without compromising protection.

Here’s what makes the difference:

• Lightweight & Flexible: Move freely without feeling restricted.
• Innovative Fit & Design: Proper coverage without unnecessary bulk.
• Durable & Long-Lasting: Gear that holds up to tough environments.
• Improved Visibility & Ventilation: Better comfort, better performance.

You need PPE that workers trust and use correctly, every time. When it comes to electrical safety, don’t settle for outdated, uncomfortable PPE. Upgrade to Enespro and give your team the protection they deserve. Contact us today to learn more.