Key Takeaway

Arc flash and chemical splash hazards don’t mix, unless your PPE is built for both. Many companies assume layering chemical suits over flame-resistant (FR) gear is enough. It’s not. Compatibility audits often miss how outer garments can turn safe layers into fuel in the wrong conditions. Lakeland’s secondary FR line, Pyrolon, solves for that.

What is a PPE compatibility audit and why does it matter?

A PPE compatibility audit reviews whether different protective garments and equipment work safely together in real-world conditions. This matters most in environments with multiple overlapping hazards, like arc flash and chemical splash.

According to OSHA, employers must assess workplace hazards and select PPE that protects against each one, individually and combined. But here’s what many audits overlook: just because two garments are compliant on their own doesn’t mean they’re safe when worn together. That misunderstanding becomes even more dangerous when you factor in how some chemical suits react near electrical hazards.

Why is it dangerous to layer chemical suits over FR clothing?

Most chemical suits, especially limited-use types, are made from plastic-based materials. That creates a serious risk around electrical hazards. As NIOSH warns, synthetic fabrics like polypropylene or polyethylene can melt or ignite during an arc flash.

Layering one of these suits over flame-resistant (FR) clothing doesn’t solve the problem, it makes it worse. The outer chemical suit can become fuel, compromising the protection underneath. Even if the base layer is fully compliant, the meltable outer layer can cause severe burns.

Kyle Kerbow, PPE product manager at Lakeland, sees this mistake often during compatibility audits.

“You can’t take a non-FR garment and put it over a primary FR and think you’re safe,” Kyle says. “That outer garment will burn like a Roman candle.”

OSHA 1910.269 backs this up, stating:

“Employees may not wear flammable clothing in conjunction with flame-resistant clothing if the flammable clothing poses an ignition hazard.”

To stay compliant, and more importantly, to protect workers, PPE must be compatible across all hazards. Not just in the lab, but in the real-world conditions workers face every day. To avoid turning protective gear into a hazard, safety managers need to understand the role of arc-neutral outer layers.

What is arc-neutral PPE and how does it improve layered protection?

Unlike standard chemical suits, arc-neutral gear is designed not to ignite or melt in an arc flash. That makes it a critical safeguard when layering over FR clothing. An arc-neutral outer layer won’t reduce the protection rating of the FR base layer, and won’t become fuel during an electrical event.

Lakeland’s Pyrolon line is built with this in mind. Each garment is tested using ASTM F1930 thermal manikin methods and meets the ANSI/ISEA 203 standard for secondary FR protective clothing worn over NFPA 2112 primary gear.

This ensures workers get layered protection that actually works together, not makes things worse. But identifying the right garments requires a broader look, not just at the gear, but at how it performs under combined hazards.

Why should PPE compatibility audits include a full hazard assessment?

Too many PPE audits stop at checking labels and certifications. But when multiple hazards overlap, like arc flash and chemical splash, those checks aren’t enough. A real compatibility audit needs to function as a hazard assessment. That means looking beyond individual garments and asking: Does this PPE work as a system in the field?

This approach is backed by both NIOSH and OSHA. NIOSH emphasizes that protective clothing should be selected and used within the context of a complete PPE program, not in isolation. OSHA adds that every item in the ensemble must integrate without reducing overall performance.

In short, it’s not just about what each piece of PPE is rated for, it’s about how those pieces perform together when hazards combine. That’s the real purpose of a compatibility audit done right. That brings us to what really matters when selecting PPE for high-risk, multi-hazard conditions.

What should you look for in PPE for arc flash and chemical hazards?

When selecting PPE for environments where arc flash and chemical splash hazards overlap, it’s important to choose garments that are proven to work safely together. Here’s what to look for:

• The outer layer should be arc neutral, meaning it won’t ignite or melt in an arc flash. 
• Garments must meet ANSI/ISEA 203 standards for secondary FR use. 
• They should be tested using ASTM F1930 thermal manikin methods to confirm flame behavior. 
• Look for sealed seams, either taped or welded, to prevent chemical intrusion. 
• The garment should be specifically designed to be worn over NFPA 2112 or ASTM F1506 certified primary FR gear. 

And just as important, here’s what to avoid:

• Meltable plastic suits, which can ignite or drip in arc flash conditions. 
• Serged or bound seams, which can fail under pressure or spray. 
• Outer layers not tested for arc flash or flash fire exposure. 

Choosing the right combination of materials, seams, and certifications ensures your PPE doesn’t just meet standards, it performs safely in real-world conditions. 

Is your PPE ready for arc and chemical hazards?

When arc flash and chemical hazards overlap, the wrong gear, or the wrong layering, can put workers at serious risk. Compliance alone isn’t enough. Your PPE must perform as a system under real-world conditions.

That’s where Lakeland’s Pyrolon line comes in. These secondary FR garments are arc neutral, tested to ASTM F1930, and designed to be worn safely over primary FR gear. Whether you need Pyrolon Plus 2 for light splash, Pyrolon CRFR for chemical and oil resistance, or Pyrolon CBFR for full hazmat-level protection, we have solutions built for cross-hazard performance.

Our technical team can walk you through your current setup, identify gaps, and recommend the right Pyrolon garments for your environment. Close the gap between safety assumptions and real-world protection, with PPE that’s engineered to handle both. Request a compatibility audit or product sample today.

FAQ

Can I wear a chemical suit over FR clothing in an arc flash environment?

Not unless it’s arc neutral. Most chemical suits are made from meltable plastics like polypropylene, which can ignite or drip during an arc flash. Even if your base layer is flame-resistant (FR), the wrong outer garment can become fuel. 

What makes a chemical suit “arc neutral”?

Arc-neutral suits won’t ignite, melt, or reduce your underlying FR protection in an arc flash event. These garments are tested using ASTM F1930 thermal manikin methods and must meet ANSI/ISEA 203 standards for secondary FR use.

Why are taped seams important in arc and chemical PPE?

Even if the fabric is chemical-resistant, seams can be a weak point. Taped or welded seams prevent liquids from seeping through stitch lines, especially under pressure. In dual-hazard environments, sealed seams help maintain full-body protection without compromising arc safety.

How do I know if my PPE is compatible across multiple hazards?

Start by asking if your gear is designed to perform as a system. Check whether outer layers are arc neutral, meet secondary FR standards, and have sealed seams for chemical splash. A compatibility audit from a technical expert, like Lakeland’s team, can help assess your setup, spot risks, and recommend safer alternatives like Pyrolon garments built for multi-hazard protection.