Warning: This article contains descriptions and images that may be graphic or disturbing to some readers. Viewer discretion is advised.
Let’s start with some numbers. A 1.2 calorie per square centimeter burn is considered to be a serious, but fully recoverable, second-degree burn; Jason Brozen’s burn was calculated at 37.5 calories. He was in a medically-induced coma for one week, in an intensive care burn unit for two weeks, unable to drive for two months, underwent intensive hand therapy for five months, was off work for seven months, and has lost function and feeling in his hands for life. This was all from an arc flash that lasted 0.125 seconds.
It happened on April 7, 2009, when Brozen installed a breaker in a main distribution panel for a new hotel pool control panel. He says he did everything wrong. He was not wearing flame-resistant clothing. He was working alone. He was wearing a heavy metal wedding ring. He had zero PPE (personal protective equipment), not even gloves, “when I should have been wearing a moon suit [full-coverage PPE].”
How did Brozen survive what should have been a fatal arc flash? He cites three key factors. The A-phase primary fuse on the transformer outside blew. He had not removed the “dead front” panel cover, which diffused the impact a bit. His clothing did not ignite.
Brozen cites the event and his recovery as a turning point. “Helping others understand and avoid the risks of arc flashes has become my mission, vision, and passion.” It’s hard to get survivors to talk about their arc flash experiences; sometimes it’s pride, often it’s PTSD. They cannot recall or do not wish to speak about what happened.
Brozen works for Tyndale USA, a supplier of arc-resistant and flame-resistant PPE, as their lead corporate safety and technical trainer. He has been a certified master electrician status for more than 28 years and is a National Fire Prevention Association (NFPA) Certified Electrical Safety Compliance Professional (CESCP). His only social media presence is LinkedIn, where he has 20,000 followers. He has been teaching the NFPA 70E Standard for Electrical Safety in the Workplace for several years. He is a keynote speaker and spoke to 67 different groups in 2024.
Brozen dispels inaccurate understandings of arc flash injuries and such myths as low voltage cannot create arc flash incidents; he was working on a 120/208 system. Burns that result when clothing ignites are the primary cause of death in arc flash incidents. There is also potential for damage to the eyes and ears, lung damage from breathing superheated air, and the effects of inhaling copper vapor.” There are also emotional and social consequences. The resulting injury will almost certainly entail acute stress disorder (ASD), which can last up to a month and may transition into post-traumatic stress disorder (PTSD), which can last a lifetime. Coworkers are stressed and worried. The family is traumatized.
The hands and face are commonly injured in arc flash incidents and the ongoing effects of these injuries are burdensome. “At least during your lengthy recovery, you’re relying on others for everything. Drive you to the doctor. Feed you. Even your personal hygiene. What are you willing to sacrifice to avert a moment’s inconvenience on the job site? By not respecting the risks of an arc flash, you’re taking a gamble. What are you willing to ante up?”
Tips for avoiding arc flash incidents, and common mistakes
Here are his top 3 tips for avoiding arc flash incidents:
1. Complacency is the #1 risk factor. It is especially problematic among older workers. Years of safe outcomes and near-misses reinforce the false notion of invincibility.
2. Training is essential. It must be structured training specific to arc flash prevention and safety.
3. Understand what “qualified” means. NFPA 70E is a primary resource for this.
Because of the prevalence and risks of complacency, Brozen lists a few common comments that indicate complacency and offers responses.
“I’ve done this a million times.” One of these times your luck will run out.
“I don’t need PPE; I’m just going to [fill in the blank].” No task that includes the risk of arc flash is so trivial that safety can be ignored.
“It’ll only take a second.” A 1 second, 60-cycle arc flash is huge; remember Brozen’s arc flash lasted only 1/8th of a second.
“We’ve made it this far with no problems.” The absence of incidents does not prove the existence of safety.
Brozen says an arc flash incident is not a single event but the culmination of a series of decisions leading up to that event, the proverbial line of falling dominoes. He also says relations between the office and the field are too often strained and can be contemptuous when they should be coordinated and mutually supportive, at least when it comes to safety.
Brozen ends his talks with a message of faith. He cites a vision of an explosion that his mother had eleven days before his incident; she drew a remarkably detailed image of an arc flash and felt compelled to pray about it. “I believe in miracles. A lot of people don’t, but I do. I know that God saved my life so that I can share this message with others because someone out there has something even more important to do than I do, and maybe I can be a part of saving their life.”
While Jason Brozen’s story focuses on the dangers of arc flash, electrical hazards aren’t limited to work inside a panel. Underground utilities—electric, gas, water, fiber optics—pose serious risks for workers in excavation, construction, and maintenance. Just like an arc flash can happen in an instant, striking an underground power line or gas main can have catastrophic consequences.
Utility strikes not only cause costly damages and service disruptions but can lead to severe injuries or fatalities. A simple call to 811 before digging can prevent disaster. Marking underground utilities and following proper excavation practices should never be skipped in the name of speed or convenience.
Brozen’s message about complacency applies here, too. Too often, workers assume they know what’s below because they’ve worked in an area before. But infrastructure changes, depths vary, and mistakes happen. The absence of an incident doesn’t mean the presence of safety.
Just like wearing proper PPE and following electrical safety protocols, taking the time to locate and respect underground utilities is a critical part of the job. Because in both cases, one careless moment can change everything.
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