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In 1960, a large global chemical company began documenting and implementing requirements for preventing injuries from electric arc flash hazards, including appropriate personal protective equipment (PPE). Methods evolved from requiring a 100% natural fiber long-sleeve shirt for a specific task to a detailed analysis with multiple flame-resistant clothing options. This paper compares the PPE required by these methods, based on hazards analysis in more than 65 manufacturing and laboratory facilities. The total costs for the example company are estimated for each method.