Why flame-resistant workwear is essential — even when you're just testing

Arc flash and electrical burns don’t wait for a second chance. Whether you’re replacing a fuse or conducting voltage testing to confirm a system is de-energised, the risk of arc-related injury is real. As ANTHONY LEVA, National Marketing Manager at TRu Brands, explains, that’s why flame-resistant workwear isn’t just for high-voltage switching or fault repair — it’s essential PPE for anyone involved in any live work, including testing.

When it comes to electrical safety, testing for dead is a key procedure that every electrician, maintenance worker or engineer performs. It’s a fundamental step to make sure a piece of equipment is de-energised and safe to work on. But it’s a procedure that carries a hidden danger. The very moment you apply your tester; you’re entering a hazardous boundary. If something has gone awry, a breaker has failed, a back feed is present, or there’s a simple human oversight, you could be exposed to a dangerous arc flash in a fraction of a second.

This is why wearing certified flame-resistant (FR) workwear during testing for dead is not optional; it’s essential.

This isn’t just best practice — it’s codified in Australian Standard AS/NZS 4836:2023 – Safe working on or near low-voltage electrical installations and equipment.

Testing is live work

A common misconception among workers is that testing doesn’t count as working live. AS 4836 puts that assumption to rest:

“Testing to prove that conductors and electrical equipment are not live shall be treated as live work and appropriate control measures applied.” — AS/NZS 4836:2023

That means when you’re probing terminals with your multimeter to confirm zero voltage, you’re engaging in live work under the standard. The risk of an arc flash event — whether from a faulty breaker, degraded insulation or simple human error — is still present. And if you’re in street clothes or non-FR hi-vis, the outcome could be fatal.

Some workers become complacent, thinking “this is a routine procedure” or “this piece of equipment should be de-energised”, but accidents frequently happen when we let our guard down. An arc flash can be triggered by something as simple as a faulty breaker, a shared neutral, or a nearby back feed and you may not realise it’s live until you make contact.

FR clothing: more than just compliance

AS/NZS 4836:2023 recommends arc-rated PPE for this exact reason:

“Arc-rated protective clothing and equipment shall be worn when working live or performing testing.” — AS/NZS 4836:2023

The keyword here is “shall”, which in the context of Australian Standards indicates a strong recommendation. It’s a clear call to action — don’t test or work live without the proper gear.

FR workwear is designed to self-extinguish when exposed to flames or arc flash. Unlike polyester or untreated cotton, which can melt or ignite, FR garments reduce the severity of burns and can be the difference between walking away or suffering life-altering injuries.

Cost vs catastrophe

An FR-rated shirt and pants set might cost $150–$300. That may seem steep for smaller operations or solo contractors — but compare that to the cost of an arc flash incident:

• Skin graft surgeries and months of rehabilitation: $100,000+
• Lost income during recovery or permanent disability
• Fines for WHS breaches under safe work regulations
• The human cost: lifelong injury or fatality
   

FR clothing is a low-cost, high-impact investment in your safety — and your life.

Don’t assume — protect yourself every time

Too often, electrical workers assume that “it’ll be fine this time” or “I’m just testing”. But AS/NZS 4836:2023 is clear: testing is live work. The risk is real, and preparation is mandatory.

FR workwear is your last line of defence. It won’t stop the arc flash — but it might stop it from ending your life. If the standard recommends it, your procedures and policies should reflect it.

If you wouldn’t work live without gloves or tools, don’t do it without certified FR workwear.

Image credit: iStock.com/sturti. Stock image used is for illustrative purposes only.