Arc Flash Injuries on Electrical Worksites: What to Do in the First Few Minutes

An arc flash can happen in a fraction of a second. The energy released — in the form of heat, light, pressure, and sound — can cause severe burns, blast injuries, and temporary or permanent vision damage, even to workers standing several metres away from the source. If you work around switchboards, high-voltage equipment, or energised panels, understanding arc flash first aid is not optional. It is part of working safely.

What Is an Arc Flash?

An arc flash occurs when electrical current travels through an unintended path in the air, creating a plasma arc between conductors or from a conductor to earth. The temperature at the arc point can exceed 20,000°C — roughly four times the surface temperature of the sun. At that heat, nearby materials vaporise, metals melt, and the surrounding air expands explosively.

Workers do not need to be in direct contact with the source to be seriously injured. The blast wave, radiant heat, and vaporised metal can cause injuries at a significant distance. This is why arc flash is one of the most dangerous — and often underestimated — hazards in electrical work.

Recognising Arc Flash Injuries

Arc flash injuries typically affect multiple body systems at once. A worker who has been exposed may present with any combination of the following:

Burns: Thermal burns from the heat flash, ranging from superficial redness to deep partial or full-thickness burns on exposed skin. Burns to the hands, face, and forearms are common. Unlike burns from direct flame contact, arc flash burns can be extensive across large areas of skin in a very short time.

Eye injuries: The intense ultraviolet and infrared light produced by an arc flash can cause photokeratitis (similar to arc eye or flash burn), temporary blindness, or permanent damage. Symptoms may not appear immediately — a worker may feel fine immediately after the event but develop severe eye pain hours later.

Blast injuries: The pressure wave from an arc flash can cause ruptured eardrums, chest injuries, and blunt force trauma if the worker is thrown backward by the blast.

Respiratory injuries: Inhalation of vaporised metal, toxic gases, and hot air can damage the airways and lungs. This may not be immediately obvious but can become life-threatening as swelling develops.

Cardiac effects: If the arc flash results in contact with the electrical source, cardiac arrest or arrhythmia may follow.

First Aid Response: Step by Step

The first minutes after an arc flash incident are critical. Follow these steps:

1. Ensure the scene is safe. Before approaching the injured worker, confirm that the electrical source has been isolated. An arc flash can trip circuit breakers, but equipment may still be energised. Never approach until a qualified person has confirmed the circuit is de-energised and locked out.

2. Call 000 immediately. Arc flash injuries are almost always serious, even when the worker appears relatively uninjured. Delayed deterioration is common. Do not wait to see how the person feels before calling emergency services.

3. Remove the person from the area safely. If the worker can be moved to fresh air away from fumes and heat, do so carefully. Handle gently — blast injuries may have caused fractures or spinal trauma.

4. Assess consciousness and breathing. Check responsiveness. If the worker is unresponsive and not breathing normally, begin CPR immediately using the Australasian Resuscitation Council (ARC) guidelines: 30 chest compressions followed by 2 rescue breaths, or hands-only CPR if not trained in rescue breaths. Use an AED if one is available on site — early defibrillation significantly improves survival outcomes.

5. Cool burns with cool running water. For thermal burns, cool the affected area with cool (not cold) running water for 20 minutes. Do not use ice, butter, cream, or any other substance. Do not remove clothing that is stuck to burned skin — leave this for paramedics. Once cooled, cover loosely with cling wrap or a clean non-fluffy bandage.

6. Protect the eyes. Do not rub or apply pressure to injured eyes. If there is debris or material in the eye, do not attempt to remove it. Cover gently with a clean damp cloth and keep the worker calm and still until paramedics arrive.

7. Monitor breathing carefully. If the worker inhaled hot gases, vaporised metal, or superheated air, airway swelling can develop over the following minutes to hours. Keep the person as still and calm as possible. Watch for any change in breathing pattern, a hoarse voice, or increasing distress — these can indicate airway compromise.

8. Keep the worker still and reassured. Even if the worker says they feel fine, ensure they are assessed by paramedics before leaving the site. Arc flash injuries involve physiological responses that may not be immediately apparent.

Arc Flash PPE: Reducing Severity Before an Incident

Arc-rated personal protective equipment (PPE) is designed to reduce the severity of arc flash burns by not igniting or continuing to burn when exposed to the arc’s energy. This includes arc-rated coveralls, face shields with arc ratings, and insulating gloves matched to the incident energy level of the task.

WorkSafe Victoria’s electrical safety guidance requires employers to assess the risks associated with electrical work — including arc flash hazards — and implement appropriate controls. Selecting the correct arc-rated PPE is a key control, as is ensuring that energised work is only performed when there is no practicable safe alternative to de-energising the equipment first.

Relevant obligations sit under the Electricity Safety Act 1998 (Vic) and the Occupational Health and Safety Act 2004 (Vic), both of which place clear duties on employers to identify and manage electrical hazards in the workplace.

First Aid Requirements on Electrical Worksites

Safe Work Australia’s Code of Practice for First Aid in the Workplace makes clear that first aid provisions must be proportionate to the nature and severity of hazards on site. For worksites where electrical work involves switchboards, high-voltage systems, or energised equipment, this means:

At minimum, at least one trained first aider should be present and accessible at all times. A stocked first aid kit appropriate to the site’s risk profile must be available. Given the potential for cardiac arrest following electrical injury, access to an automated external defibrillator (AED) is strongly recommended on any larger or higher-risk electrical worksite.

Workers should also receive regular first aid refreshers. Training completed several years ago may not reflect the current ARC resuscitation guidelines, and knowledge of specific electrical injury response — including arc flash — may not have been covered in older course content.

Keep Your Skills Current with AB First Aid

AB First Aid offers nationally recognised first aid training at our training centre in Tullamarine, Victoria. Our courses are practical and grounded in real worksite scenarios — including the incidents that can occur when working with electricity.

Whether you are renewing your qualifications, onboarding a new team member, or arranging group training for your workforce, we have public course dates and workplace options available throughout the year. View our current schedule or book a course at abfirstaid.com.au. Group bookings are welcome, and we can discuss tailoring content to the specific hazards in your industry.

References

• WorkSafe Victoria. Electrical Safety. worksafe.vic.gov.au/electrical-safety
• Safe Work Australia. First Aid in the Workplace: Code of Practice. safeworkaustralia.gov.au
• Australasian Resuscitation Council. Guideline 8 — Cardiopulmonary Resuscitation. resus.org.au
• Victorian Government. Electricity Safety Act 1998. legislation.vic.gov.au
• Safe Work Australia. Managing the Risks of Plant in the Workplace: Code of Practice. safeworkaustralia.gov.au