March 28, 2025 How PPE Helps Manufacturers Reduce Electrocution Risks

Volume 28 | Issue 1

Proper PPE, combined with training is essential for safety in manufacturing. 

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Electrocution risks in the workplace are a serious concern, particularly in the manufacturing sector, where workers are exposed to high-voltage equipment daily. While construction sites are often perceived as the most hazardous for electrical accidents due to their changing environments and temporary wiring, manufacturing facilities also present serious and unique risks to workers. Factory floors and production lines are controlled environments with established workflows, but this consistency can lead to complacency, making workers underestimate the potential electrical dangers.

The severity of this issue is clear. The manufacturing industry ranks among the top sectors with high fatalities, and 28% of electrical fatalities occur on industrial premises, underscoring the vulnerability of workers in these environments. Other industries face risk as well. According to Occupational Safety and Health Administration (OSHA) and Bureau of Labor Statistics (BLS) data compiled by the Electrical Safety Foundation International, 74% of workplace electrical fatalities occur in non-electrical occupations, showing that even workers who don’t directly handle electrical systems can be at risk.

Beyond the human toll, electrical incidents can have severe financial repercussions for businesses. According to the BLS, 2.6 million nonfatal workplace injuries and illnesses were reported in 2023, with over 900,000 cases involving days away from work. These incidents disrupt operations, reduce productivity, and lead to increased insurance premiums. Furthermore, non-compliance with OSHA and National Fire Protection Association (NFPA) 70E standards can result in substantial fines and legal liabilities.

However, electrocution risks are preventable with the right safety training, strict adherence to regulations, and proper use of personal protective equipment (PPE). PPE plays a critical role in mitigating electrical hazards and, when combined with a strong safety culture, can significantly reduce the likelihood of injuries or fatalities.

Understanding electrocution risks in manufacturing

Manufacturing environments are filled with high-voltage machinery and electrical systems, which pose significant risks to workers, including arc flash injuries. Unlike construction sites, where hazards frequently change due to evolving job sites and temporary wiring, manufacturing facilities operate in a more stable and controlled setting via factory floors and production lines. However, this consistency can create a false sense of security, leading to lapses in safety practices within established workflows.

Most electrical accidents and injuries happen abruptly or unexpectedly, especially when working with or around electrical live circuits or current. This is why it’s vital to assess each work task, identifying what electrical safety is required that might help lower the risk factors of an incident occurring with having the proper protective equipment.

One of the most common causes of electrical injuries in manufacturing is improper Lockout/ Tagout (LOTO) procedures. LOTO violations have led to severe and sometimes fatal incidents where machines were unexpectedly energized during maintenance. Even experienced workers may bypass safety protocols to speed up operations, increasing the risk of electrocution.

Additionally, equipment failures can expose workers to live electrical parts. If machinery malfunctions without warning, employees may inadvertently come into contact with hazardous voltages, leading to severe injuries or fatalities. These risks make it essential for manufacturers to enforce stringent electrical safety measures, including the use of appropriate PPE.

Steps to protect workers and reduce electrocution risks

Preparation is the first step in prevention. The following best practices can help ensure safety when working with or around electricity.

1. Conduct a risk assessment
   The first step in preventing electrocution incidents is conducting a thorough risk assessment. This assessment identifies potential electrical hazards in the workplace, evaluates voltage levels, and determines the proximity of workers to live electrical parts. By understanding these risks, employers can implement appropriate safety measures and ensure that workers are equipped with the necessary PPE.

   A risk assessment should include:

   • Evaluating the presence of live electrical circuits
   • Identifying potential arc flash hazards
   • Determining the likelihood of accidental contact with electrical components
   • Assessing environmental factors, such as moisture or confined spaces, which can exacerbate electrical hazards.

     By proactively identifying these risks, manufacturers can implement preventive measures that minimize the likelihood of accidents and ensure workers are adequately protected.

2. Select the right PPE for the job
   Once risks are identified, selecting the appropriate PPE is essential to protect workers from contact with electrical hazards, including shock, arch flash, and fire protection. The type of PPE required depends on the specific risks present in the workplace. Some key categories of PPE that can reduce electrocution risk include:
   • Insulated gloves: Designed to prevent electric current from passing through the body, insulated gloves are essential when working with live electrical system
   • Voltage-rated tools: These tools provide an additional layer of protection, preventing accidental electrical contact
   • Flame-resistant (FR) clothing: Arc-rated FR clothing helps protect workers from burns in the event of an arc flash
   • Arc flash suits: These suits provide comprehensive protection against extreme heat and thermal hazards associated with arc flashes
   • Closed-toe safety shoes with non-conductive soles: These shoes minimize the risk of electrical currents traveling through the worker’s body
   • Insulating mats: Used in high-voltage areas, these mats provide an additional barrier against electrical grounding.

     PPE must comply with OSHA and NFPA 70E standards to ensure maximum protection. Employers should regularly inspect PPE for wear and damage, replacing any equipment that no longer meets safety requirements.

3. Implement supporting safety practices
   While PPE is essential, it should be part of a broader safety strategy that includes training, enforcement of safety protocols, and ongoing risk management. Key supporting practices include:

Comprehensive electrical and LOTO training

• • Workers should receive regular training on recognizing electrical hazards, following safe work practices, and responding to emergencies.
  • Employees must be trained in proper LOTO procedures to ensure machinery is fully de-energized before maintenance work begins.

Circuit protection measures

• • Install circuit breakers and fuses to prevent overloads and short circuits that could cause fires or electrocution.
  • Ensure all electrical systems are properly grounded to reduce shock hazards.
  • Use Ground Fault Circuit Interrupters (GFCIs) in high-risk areas to cut off power in case of a fault.

Avoiding overloaded circuits

• • Proper load management is essential to prevent overheating and electrical failures.
  • Conduct routine inspections of electrical panels and wiring to identify wear, corrosion, or damage before issues arise.
  • Reduce reliance on extension cords and instead install permanent wiring solutions where needed.

Using the right equipment

• • Use explosion-proof electrical devices in environments with flammable substances.
  • Ensure all electrical equipment meets OSHA and NFPA 70E safety standards.

Adopting safe work practices

• • Never bypass safety mechanisms such as interlocks or machine guards.
  • Maintain clear access to electrical panels and emergency shutoff switches.
  • Avoid handling electrical equipment with wet hands or working in damp conditions.
  • Post warning signs near electrical hazards to reinforce safe work practices.
  • Ensure that emergency response procedures for electrical incidents are well-documented and communicated to all employees.

By implementing these practices, manufacturers can build a culture of safety that prioritizes hazard awareness and proactive risk mitigation.

Proactive prevention for a bright future

Electrocution risks in manufacturing are a serious concern, but they’re preventable with the right combination of safety protocols and personal protective equipment. A proactive approach that includes conducting risk assessments, selecting appropriate PPE, and implementing comprehensive safety programs can significantly reduce the likelihood of electrical injuries and fatalities. By fostering a strong safety culture, manufacturers can protect their workers, improve operational efficiency, and ensure compliance with regulatory standards.

About the Author:
Randy Dombrowski is the Director of Safety Services for Sentry Insurance. Sentry provides insurance and risk management solutions to manufacturing businesses throughout the country, helping companies maintain safer workplaces and reduce liability risks.

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