The booming electrification of everything requires customized PPE for those who make it work.

In a world racing toward a more sustainable and electrified future, the landscape of society is undergoing a monumental transformation. The electrification of society is not merely a trend; it's a necessity, driven by the urgent need to combat climate change and reduce our dependence on fossil fuels. This means the adoption of electricity as the primary energy source for various applications and industries. In its wake come new professions that have one thing in common: The need of protection.

The electrification is paving the way for the emergence of new industries, reshaping our economic landscape with innovative businesses and new job opportunities. The renewable energy sector, in particular, is experiencing unprecedented growth, ushering in industries such as solar and wind power generation, battery and electric vehicle manufacturing and data centers.

The International Renewable Energy Agency (IRENA) suggests that the renewable energy sector could employ up to 42 million people globally by 2050. Another analysis by the World Economic Forum projects that the shift to electric vehicles could create up to 11 million new jobs by 2030, with potential growth in manufacturing, infrastructure development, and related services.

New Professions in the Electrified Era

With this electrification surge comes the birth of new professions - those charged with powering our world with electricity. And the very nature of electrified professions demands a shift in how we think about workplace safety.

• Operating within the realm of high-voltage equipment, workers are exposed to the imminent dangers of electric shock, arc flashes, arc blasts and explosions.
• The use of high-voltage batteries in electric vehicles (EVs) can lead to the development of new types of fires, requiring specialized methods for detection and extinguishing.
• The use of hazardous chemicals in battery manufacturing introduces the risk of chemical splashes.
• Contact with hot equipment and heat conductive materials poses a significant risk of burns.
• Workers in power plants or substations may be susceptible to heat-related illnesses due to high ambient temperatures.
• Workers operating wind farms, often offshore, face exposure to unpredictable and extreme weather conditions including high winds, cold and extensive wet conditions.

Combined risks require innovative protection solutions

It is not only the risks themselves, but their combination that poses an additional challenge. For instance, the manufacturing of car batteries with high density often uses chemicals such as lithium, cobalt, nickel, and other hazardous material compounds, making the batteries highly flammable and explosive if not handled properly. Workers are potentially also exposed to extremely dangerous arc flash incidents. According to industry experts, highly dangerous incident energy of up to 29 cal/cm² is generated when attaching batteries with the engine in EV car manufacturing. When installing charging stations for EVs, the energy can even exceed 50 cal/cm². Direct contact with these incident energies would end fatally if workers were not protected sufficiently.

Renaissance of Direct Current (DC)

One hazard that stands out in all of the new professions is the renaissance of direct current (DC) as the dominant electric current in new applications and industries: Many renewable energy sources, such as photovoltaics and wind power, initially generate DC. It can be more efficient for transmitting electricity over very long distances, such as from offshore wind farms, because it has fewer line losses. And because electric vehicles need DC to charge their batteries, the charging infrastructure and on-board systems of the vehicles are based on DC power technology.

"It all starts with the needs of workers to ensure their maximum protection. Across all electrified industries, extensive research is underway to better understand the risks associated with DC. This includes reviewing emerging standards and conducting risk assessments in the field," says Miguel Calixto, Product Specialist for GORE-TEX Professional Fabrics. "We are working closely with electrical industry partners and health and safety experts to have a clear understanding of the new hazards and risks in the workplace and the safety requirements for appropriate PPE to keep electrical workers safe."

Sensitizing employees for the risks associated with DC

Moreover, increasing awareness across the workforce about the dangers associated with DC is crucial. "Contact with DC is more dangerous than alternating current (AC)," explains Dr. Oliver Polanz, Head of Health, Safety, Environment, and Quality at SPIE Germany and Central Europe. "DC can cause continuous muscle tetanus, making it more likely to “freeze” a victim in a shock scenario. Thus, we make an extra effort to sensitize and train our employees for DC-related dangers."

Forming a stable carbon layer to protect electrical workers

With all understanding and protection, it is the technology in several millimeters of garment that to make the new work more productive and improve employee´s safety when potentially exposed to electrical hazards. GORE-TEX Professional Fabric’s PYRAD® product technology offers bespoke protection for workers in electrified industries: The technology is based on a physical effect and consists of countless small reactive dots homogeneously distributed over the membrane. When the dots are strongly heated by a sudden flame or arc incident, they react and expand by more than 10 times their original size to form a stable, gapless carbon layer that effectively inhibits heat flow.

Combined protective technologies for mixed hazards

Since workers are often confronted with a mix of hazards, many Gore product technologies combine different ways to protect them and provide comfort at the same time. "Working on an offshore wind farm requires extreme weather protection, full hazard protection and the ability to move in confined spaces while being physically active. Working at the side of the road in 30°C has the same hazard protection requirements, but different weather protection. This requires customized PPE depending on the conditions," says Alexandra Fiss, Strategic Marketing at GORE-TEX Professional Fabrics. "Any gain in breathability, weight and freedom of movement has a direct impact on worker safety, morale and motivation." As we chart our course toward an electrified future, it's important to keep sight of the human element - the men and women who are driving this transformative change. More research needs to be done on the hazards that come with it to protect those who make it work in their daily jobs. Not only for their safety, but to enable society's journey to a decarbonized world.

Norwegian-based company WENAAS and GORE-TEX Professional developed a smart repair kit for GORE-TEX PYRAD® garments helping to expand the useful product lifetime.

The greatest environmental impact in a lifecycle of personal protective equipment occurs during production and distribution. Extending longevity, or useful life, of a product is therefore  the single most influential factor to improve its environmental impact. This is especially true if a product can be repaired and re-used again. Following this spirit, Wenaas, an international supplier of workwear solutions from Norway, together with GORE-TEX Professional, developed a smart repair kit for arc rated GORE-TEX PYRAD® personal protective equipment (PPE) to help their customers prolong the garments' product life.

Electrical workers often need to move through difficult, thorny terrain to locate a fault on the power network and climb high poles. During these activities their PPE can get stuck behind something sharp or spines, which, despite the robustness of the material, could result in a puncture or small tear of the outer fabric. While the garment overall would still be fit for use, a tiny puncture could result in a potentially dangerous situation for the wearer in case of an electric arc. By applying the patch, propagation of the tear is avoided, and garment lifetime extended.

"Norwegian electrical utility workers came to us with a problem: some of their employees had small punctures in their Wenaas GORE-TEX PYRAD® garment from walking through dense forest before reaching their service location", illustrates Kristin Lien, product developer at Wenaas. "Together with Gore we concluded that it makes financially and environmentally no sense to replace the entire garment. GORE-TEX PYRAD® garments are top of the line. Our collective goal is to let customers keep their garments as long as possible before having to replace them. Therefore, we developed the repair kit — a win-win solution: cost-effective as well as a very sustainable solution." 

repair kit for the garment

The repair kit consists of four GORE-TEX PYRAD® fabric patches: two round patches (diameter 7,6 cm) and two square patches (10x5 cm). These allow for the repair of small and medium-sized punctures or tears of the fabric — for larger damages two or more patches can be combined. The kit comes in two color versions: fluorescent yellow and navy blue. No special skills are involved to repair the garment: the patches have flue on the backside — a short instruction video shows that all that's needed is a hairdryer and/or an iron to permanently attach the patch. After repair, the risk of harmful incidents is avoided by using a protection patch made of GORE-TEX PYRAD® arc-protective materials and can be washed as usual. And in the rare case the fabric is damaged in the exact same place again, a new patch can even be applied over the previous patch. "The feedback from our customers is very positive", concludes Lien, "the repair kit absolutely solved their problem."

Jonas Andersson, sales Associate at GORE-TEX Professional says: "Our sustainability approach is about providing exceptional long-lasting products while at the same time reducing the environmental footprint. The idea of the repair patch is to avoid further tear propagation which could result in losing the required protection. And through these patches, users can contribute to our effort and do something meaningful."

For further product information about the repair kit, visit https://www.wenaas.com/en/products/rep-set-goretex-pyrad-flouresent-yellow-0-10930-19819-32 

about arc rated gore-tex pyrad® technology

Arc rated GORE-TEX PYRAD® garments are durably waterproof and reliably protect electrical workers against the thermal hazards of an electric arc. They stay lightweight and comfortable even when wet. Up to 45% lighter when wet or dry than other products of their protective class, arc rated GORE-TEX PYRAD® garments feel less bulky to wear leading to more wearer acceptance. The garments provide maximum comfort with the highest protection level, so electrical workers remain safe – no matter the challenge, and no matter the weather.

about wenaas

For more than 80 years, Wenaas has been making workwear and personal protective equipment for women and men in a variety of sectors, with the aim of making their working day securer and more comfortable. We know that our products can mean the difference between life and death, and we never compromise in our product development. We have made a film that highlights a broad range of protective equipment and work clothes in use in different sectors where the right clothing is essential for a good, safe working day. https://www.wenaas.com/en/

about gore

W. L. Gore & Associates is a global materials science company dedicated to transforming industries and improving lives. Since 1958, Gore has solved complex technical challenges in demanding environments — from outer space to the world’s highest peaks to the inner workings of the human body. With more than 12,000 Associates and a strong, team-oriented culture, Gore generates annual revenues of $4.5 billion. www.gore.com

A stormtrooper look-alike working the streets, seemingly having just escaped the movie studio. A jacket with an illuminated city map with a Klimt-style aesthetic. A construction worker as strong as Godzilla. Science fiction? Or reality? Visionary, certainly, but not pure fantasy. These and many more are photorealistic visualizations of workwear concepts GORE-TEX brand created with AI and partners.

"At Gore, we always start with the end users. Where do they work? What are their needs? What are their pain points? How can we improve comfort? Our focus goes beyond just laminates, tapes, and textiles - we are committed to understanding the daily challenges our end users face and then collaborate with leading manufacturers to constantly improve workers' protection and comfort," says Leonard Schlichting, Business Leader Workwear at Gore.

from street operator to heritage handyman - there is not the "one" future of workwear

During its process, the GORE-TEX fabrics' team collaborates closely with leading workwear manufacturers, think tanks, research agencies, universities as well as end users. The helicopter view of megatrends and macroeconomic market research is blended with hands-on information, resulting from interviews with end users from different fields that are confronted with "their" specific challenges and risks day in and out. In cooperation with their designer Jo Baumgartner at the consultancy Q'rateur, the pile of information and future signals was condensed into four future personas.

four personas as archetypes of special functional needs

These future personas symbolize different design trends, each representing an archetypal end user with very specific protective needs. They add a human touch and enable the team to put themselves into the shoe of each end user. Moreover, they are a perfect canvas to investigate and explore new ideas, some radical, some pragmatic. These four personas were dubbed the Street Operator, Augmented Wireman, High Performer and Heritage Handyman. The Street Operator, for example, has a tough job as he faces challenges on the road, is exposed to hot or wintery weather, pouring rain and heavy traffic and walks dozens of kilometers per day. Smart comfort elements such as active heating and cooling help to regulate body temperature, enhanced safety vests with integrated protectors and active lighting protect against traffic hazards and integrated lighting helps to illuminate the workplace hands-free. The Augmented Wireman needs to move heavy weight around and may have to enter restricted areas in production facilities. His gear includes technical features such as bionics, smart access devices, data screens and smart goggles with augmented reality included.

AI offers tremendous opportunity for swift visualization

How do these folks look like? "In the past, it would have taken many boards, flipcharts and prototypes in tedious work to visualize concepts for such personas. A tool that has opened vast possibilities in design and quick visualization is Artificial Intelligence (AI) for us" says Reza Jamshidi Azad, garment concept designer at Gore. It has evolved from a toy to play with to a serious tool. The key term here is "generative design," a process that uses AI algorithms and cloud computing to quickly develop photorealistic visuals.

stylish design is increasingly becoming a differentiator in workwear

AI offers not only speed and endless inspiration, but also adds an element of style.  "We know from research that design is increasingly becoming a differentiating factor in purchasing decisions. Workwear is no longer just about what workers have to wear for safety, but what they want to wear" Reza continues. "AI helped us to add this aesthetic element for end users to not only look good at work, but also at after hour drinks."

So, will we see these concepts in reality? "This is not on Gore to decide. We are a material science company and develop technologies for functional clothing, but not a manufacturer of workwear. As a consultant and sparring partner for the manufacturers though, we can help spark new concepts and styles that are supported by our technologies" Schlichtling sums up. "But who knows? I love to dream big and could not be prouder to meet an end user wearing one of these garments one day."

When it comes down to selection of PPE, one of the most important criteria is “comfort & lightweight”.

Especially when the consequences of a non-used PPE can result in severe injury or death, the only proper PPE is the PPE that is worn and ideally loved by the users.
An electrical arc flash is definitely such a high risk scenario. For this reason, the risk assessment for the specific workplace is key. With more detailed technical evaluation done in the last few years, many utility companies have decided that they need a protection upgrade from class 1 to class 2 (IEC 61482 box test) or even higher.

Surprisingly the protection was often upgraded for the jackets only, while the trousers stayed at class 1 protection- despite the risk evaluation would require a class 2 protection. When discussing this gap there are multiple official explanations: “the arc typically hits the upper body”, “there is some overlap of jacket and trousers”, “the trousers have pockets with additional material, giving higher protection anyhow” and others.

Off the records, the truth is different: “you can put off your jacket easily when you are not in a risk situation- but you don’t undress your pants on the street. People don’t accept uncomfortable and too warm multilayer trousers”.

So sometimes there is an accepted and tolerated risk to expose workers to a threat with garments that may not protect them in the worst case.

To extinguish the gap between best protection and comfort & wearer acceptance, Gore has developed the PYRAD technology. Expanding from our core of laminates for rainwear application, we have created a lightweight, single layer Gore PYRAD® fabric for the everyday workwear use. Garments made from this single of Gore PYRAD® fabric easily protect against class 2 arc exposure and have an ATPV rating of > 35.

We claim this to be the lightest weight and most comfortable single layer arc protective fabric on the market- suitable for everyday use also in warm condition or heavy workload.

I decided to challenge this positioning about comfort and give it a personal try. I´m not familiar with electrical working but I have a good sense of comfort check in mountaineering and other sport activities. So the plan for the challenge was an extended alpine tour in a GORE PYRAD arc rated workwear trousers:
Climb Germany´s highest mountain Zugspitze and continue with the alpine climbing traverse (up to grade UIAA 3) of the 8 km famous ridge “Jubiläumsgrat” in one push as a nice daytrip. Guidebooks calculate 7-8 h for the Zugspitze (via Höllental & Ferrata) and 6-10 h for the ridge from Zugspitze to Alpspitze.

The ridge is extremely exposed with hundreds of meters steep terrain on both sides of the sometimes only 40 cm wide ridge- it requires extended mental focus and concentration as there is no option for mistakes- similar as for an electrical worker who needs stay focused on his job. No-one wants to create a blackout in a city or industrial plant with an arc because of being distracted by discomfort.

The ascent of Zugspitze on the other hand (at least if you do it in 4 h as we did) gives you some sweat and physical effort- also as a worker who needs to carry heavy equipment and work hard.

The overall time for the main trip was 8,5 h bottom up + traverse to Alpspitze (followed by an epic, not measured time for the 1900 m descent). Temperature was 14 ° C at 4 o clock in the morning, wet conditions (no issue for the PYRAD pants) through the tunnel system of the Höllental, between 20-28 °C during the day and significant sun exposure.

My conclusion after an overall 3178 m uphill and 27 km overall distance:

1. Hivis arc rated trousers are not very common in alpine environment and give you many surprised comments along the climb
2. The overall comfort was pretty good given the conditions and the workload. Comfort was even better than with my normal polycotton workwear trousers which feel much more sweaty.
   Of course a modern, ultra-lightweight, high stretch Gore wear running trousers is more comfortable- no doubt. Gore PYRAD® technology is great and a significant step towards comfort in PPE, but it can´t do miracles. Stay realistic! However the Gore PYRAD® trousers were comfortable and “fast” enough to pass by all the other climbers that took the first cable-car up in the morning to save the 2200 m Zugspitze climb. Great gear for such a protective garment indeed!
3. If you decide for the proper sizing, choose a not too tight fit. The inner side of the fabric may stick a little bit to the skin when you are sweating a lot and the fit is too tight (as my trousers was) – just as a too tight jeans will stick.

Gore arc rated PYRAD garments for allday use (in contrast to PYRAD rainwear for bad & cold weather) are commercial available at #BSD in Dresden, #Iturri and #vanHeurck (they even integrate stretch panels into the garments).