OSHA 1926.97: Electrical protective equipment

Electrical Rubber PPE – Quick Reference

1. Seamless Construction & Clear Labeling: OSHA 1926.97

• Insulating rubber items—gloves, sleeves, blankets, mats, covers, and line hose—must be made without seams.
• Each must be marked with:
  • Class rating (00 to 4),
  • Type (Type I = non‑ozone-resistant, Type II = ozone‑resistant),
  • Optional: maker’s name and size.
• Markings must be nonconductive. Gloves are marked only on the cuff.

2. Electrical Proof Testing

• Gear must withstand specified AC/DC test voltages (see Tables E‑1 & E‑2).
• Typical test duration: 3 min (mats: 1 min).
• Gloves require a separate AC test after soaking in water for 16 hours, with current limits strictly enforced.

3. Ozone Resistance for Type II

• Rubber must resist ozone without cracking, pitting, or deterioration.

4. Integrity & Visual Requirements

• Equipment must be free from flaws that harm insulation.
• Minor cosmetic defects (e.g., indentations or embedded bits) are acceptable only if they flatten under stretch or move with the rubber.

OSHA (1926.97(a)(3): Workmanship & Finish

• Rubber insulating gear must be free from defects that impair insulation.
• Minor surface imperfections—like small bumps, indentations, or embedded particles—are okay only if:
  1. They flatten out smoothly when stretched, or
  2. Any embedded debris moves flexibly with the rubber when bent.

Compliance with ASTM standards (e.g., D120, D178, F1236) is accepted as meeting these quality requirements.

OSHA 1926.97(b): Design Rules for Other Electrical PPE

• Any non-rubber insulating gear must safely withstand all expected voltages, including occasional surges.
• It must also pass a leakage-current test at the maximum voltage it will face, producing no more than 1 µA per kV.

OSHA 1926.97(b)(2): Notes on Insulation Equipment

• Only for primary insulation gear, (not secondary/brush-contact tool).
• When under AC voltage, leakage current includes:
  • Capacitive currents (from the material itself),
  • Surface leakage (minimal if the gear is clean/dry),
  • Negligible conduction current.
• Plastic guards meet requirements if they comply with ASTM F712‑06/11.

In‑Service Care & Usage

1. Ongoing Upkeep
   • Equipment must always remain safe and reliable.
   • Rubber gear must operate within voltage limits defined in Table E‑4.
2. Routine Inspections
   • Check gear daily before use and after any potential damage.
   • Gloves require an air‑leak test.
   • Follow ASTM F1236 visual inspection techniques.
3. Grounds for Removal
   • Don’t use equipment with holes, tears, embedded debris, ozone damage, or surface changes like swelling, hardening, softening, or stickiness.
4. Repair & Retesting
   • Any suspect gear must be taken out of service, cleaned, repaired, and electrically retested per Tables E‑4/E‑5.
5. Glove Protection Rules
   • Protector gloves are mandatory over insulating gloves—except for Class 0 (under 250 VAC) and Class 00 (under 375 VDC) during tasks requiring fine dexterity.
   • If used without protectors, gloves must be retested before reuse.
6. Testing & Certification
   • Rubber gear must undergo periodic electrical testing: gloves every 6 months; other gear every 12 months, plus after repair or damage.
   • Employers must keep records or mark gear to certify testing, including dates and outcomes.

Maintenance, care & Certification: Rubber Insulating Gear

(OSHA, ASTM F479, F496)

Repairs & Allowed Modifications

• Used gear failing inspection/testing cannot be used—unless modified as follows:
  • Line hose: Cut away damaged sections.
  • Blankets: Trim out defective parts; remaining intact section must be ≥ 22″× 22″. Patching allowed if it restores full integrity.
  • Gloves & sleeves: Small cuts or surface flaws may be patched or treated with approved compounds; glove repairs limited to the wrist area between the edge and reinforced band.

Post-Repair Testing & Certification

• All repaired gear must pass electrical retesting before being used again.
• Employers must certify each item after testing—tracking test date, gear ID, and outcome—using marks or logs accessible to employees and OSHA.

AC Proof-Test Voltage Table (Gloves Only)

Class	AC Test Voltage	Max Current (mA)
00	2,500 V	8 mA @11″
0	5,000 V	8, 12, 14, 16 (varies by size)
1	10,000 V	14, 16, 18
2	20,000 V	16, 18, 20
3	30,000 V	18, 20, 22
4	40,000 V	22, 24 (16” & 18”)

 

DC Proof-Test Voltages for Rubber Insulating Equipment

Each class of insulating gear must withstand the following direct-current (DC) “proof-test” voltages:

Class	DC Proof-Test Voltage
00	10 kV
0	20 kV
1	40 kV
2	50 kV
3	60 kV
4	70 kV

Important note: These DC voltages apply only to gloves, sleeves, mats, and blankets—not to rubber insulating line hose or covers. For those, a suitable DC voltage must be used—high enough to verify safe use at the maximum operating voltages listed in Table E‑4. ASTM D1050‑05 and D1049‑98 offer further guidance.

 

Glove Water Immersion Levels (Table E‑3)

To ensure proper testing:

• Gloves (turned right-side out) are filled with water and immersed so that the water reaches a specific height from the cuff:

Glove Class	AC Test	DC Test
00, 0	38 mm (1.5″)	38 mm (1.5″)
1	38 mm (1.5″)	51 mm (2″)
2	64 mm (2.5″)	76 mm (3″)
3	89 mm (3.5″)	102 mm (4″)
4	127 mm (5″)	153 mm (6″)

Water level is measured from the cuff edge (±13 mm), and may be increased up to 25 mm in very humid or cold conditions.

Voltage & Retesting Guidelines (Table E‑4)

Rubber insulating gear must meet these voltage standards and undergo regular retests:

Class	Max Voltage Use (AC)	Retest AC	Retest DC
00	500 V	2,500 V	10 kV
0	1,000 V	5,000 V	20 kV
1	7,500 V	10,000 V	40 kV
2	17,000 V	20,000 V	50 kV
3	26,500 V	30,000 V	60 kV
4	36,000 V	40,000 V	70 kV

Retests must apply voltage continuously for 1 to 3 minutes per OSHA standards.

Testing Frequency for Rubber Insulating Equipment

Equipment Type	Test When…
Line hose	Suspected loss of insulation/after repairs
Covers	Suspected insulation issues/after repairs
Blankets	Prior to initial use, every 12 months, damage is suspected/post-repair
Gloves	Before first use, every 6 months, after damage suspicion/post-repair/after use without protector gloves
Sleeves	Prior to initial use, every 12 months, after damage suspicion/post-repair

Note: Every unused gear that tested but not issued, must retest within 12 months before use.