Our sites have two selections for AF PPE, a light weight coverall rated just over 12cal + a 10cal face shield therefore the combined limit is 10cal. The second choice is a heavy 40cal suit. Normal daily ware is non-arc flash rated natural fibers. We typically find many locations just over the light weight PPE limit. Mitigation may or may not be possible. These locations are typically associated with troubleshooting activities so increasing the working distance is not an option. Protection based mitigation is possible in some cases but not all. How have others been handling results just above a certain PPE limit? We feel requiring a worker to jump from 10cal to 40cal PPE is not practical. Given all the conservatism built within the standard (1584) and studies one would think a tolerance or +/-range could be applied. The question is how much?

I just thought I would let you know that a 12 cal shield exists and would compliment your existing coverall arc rating. The 12 cal shield I'm referring to is manufactured by the Oberon Company and will offer you a higher visual light transmission than your existing 10 cal shield. Furthermore, the Oberon shield is manufactured with Polycarbonate, NOT Propionate (allows for Anti-Scratch and many many more benefits).

When you say "heavy 40cal suit", you're likely referring to a FRT solution. 40 cal suits are available that way considerably less. The lightest weight 40 cal suit that I'm aware of is only 12.1 ounces per square yard (Oberon's ARC40 with an ATPV of 49 cal).

There are lots of options for systems between 10 and 40 cal/cm2. Find something that suits your needs (No pun intended).

Mitigation is always possible. all the methods are just not commonly known by most companies.