From Risk to Reliability: Improving Rope Safety in Energized Environments

The tools and equipment employed by electrical workers must possess the necessary insulating properties to ensure user safety. One such tool, dielectric rope, can be overlooked as a component of electrical safety, but modern standards and rigorous testing protocols are transforming the way this type of rope is designed, used and maintained.

The transition from use of traditional synthetic ropes (e.g., double-braided polyester or polypropylene with wax or overlay finishes) – which can absorb contaminants and moisture, thereby significantly reducing their insulating properties – to dielectric ropes represents a paradigm shift in safety. Just as hot sticks, fiberglass-reinforced plastic (FRP) tools and arc-rated PPE are subjected to strict maintenance and testing protocols, dielectric ropes must be treated with the same level of scrutiny and care. These ropes are increasingly being used as FRP tool replacements as they can offer lower weight and cost as well as greater flexibility in length and load-bearing capacity.

The remainder of this article will explore relevant global safety standards, the growing industry shift toward insulating rope with verified dielectric properties, and proper maintenance and handling practices to help ensure long-term dielectric rope safety in high-voltage environments.

Key Global Standards
Dielectric rope must undergo rigorous testing to confirm its ability to withstand high voltages, resist contamination and maintain insulating properties over time. These standards outline the requirements for dielectric tools and equipment, including rope:

• IEC 62192:2009: “Live working – Insulating ropes”
• ASTM F1701-12: “Standard Specification for Unused Rope with Special Electrical Properties”
• IEEE 516-2021: “IEEE Guide for Maintenance Methods on Energized Power Lines”
• NFPA 70E and CSA Z462 (arc flash standards)

Misleading Claims and Real-World Testing
For decades, standard synthetic ropes have been assumed to be nonconductive based on their material composition. Real-world testing, however, has demonstrated that these traditional ropes can absorb moisture, dirt and other contaminants, turning them into potential electrical conductors.

Further, lack of awareness and regulation in this area has resulted in the following:

• False marketing of some ropes, claiming that they are dielectric or insulating even though they have never been rigorously tested.
• Erroneous assumptions that test results from one diameter of dielectric rope apply to every diameter.
• Exposure of traditional ropes to water, mud and oil, compromising their insulating properties.
• Dielectric ropes being treated, handled, maintained, tested and inspected differently than hot sticks and FRP tools.

Dielectric Ropes as Part of an Electrical Safety System
A true dielectric rope is designed, tested and maintained like other insulating tools. This means:

• As with any tool used in energized or potentially energized environments, a dielectric rope should be routinely tested in dry and wet conditions to validate its insulating properties and fitness for use.
• All rope must be properly stored, cleaned and handled to prevent contamination.
• It is critical to perform a visual and electrical inspection of individual ropes prior to each use.
• Electrical workers must be trained to recognize the risks of using non-dielectric or contaminated ropes.

Industry Adoption: 6 Common Barriers
As dielectric rope technology advances and global standards become more defined, a growing number of utilities and contractors are adopting these ropes as part of their high-voltage operations. Yet industry-wide adoption continues to be slowed by six common barriers.

1. Resistance to change. Some safety managers and field supervisors still operate under the belief that conventional synthetic ropes are good enough, largely because serious incidents involving conductive ropes are rare or undocumented. This perspective overlooks the risks to human safety posed by contamination and environmental degradation of synthetic rope. In other words, just because a rope has not failed yet does not necessarily mean it is safe to use.

2. “We work de-energized, so we do not need dielectric rope.” OK, but what about the risks of induction and accidental re-energization from lightning strikes and switching errors? In several documented instances, ropes were accidentally energized during what was thought to be de-energized work. Utility customers who use improperly installed generators during power outages can unintentionally cause reenergization unbeknownst to the utility. The best approach is to treat all systems as potentially energized and use the safest possible ropes and other tools for the job at hand.

3. “We work in a mostly dry climate, and we never work when it rains, so we do not need to test our dielectric ropes in wet conditions.” Wet testing is the only way to identify tool contamination during periodic testing. Additionally, tools that perform well under wet testing conditions can offer greater protection against poor storage conditions, not just high humidity and rain events.

4. Incorrect assumptions about new technology. Employers and employees might assume that utilizing dielectric ropes requires special tools, training or operational changes. This misconception can lead to the false belief that dielectric ropes are niche products rather than necessary tools for hazardous, everyday tasks. In reality, numerous dielectric ropes are engineered for compatibility with standard hardware and work practices while offering enhanced safety margins.

5. Financial hurdles and reactive safety cultures. High-performance dielectric ropes are often more expensive than standard ropes, especially when testing and inspection are factored in. Initial cost sensitivity could preclude employers from fully considering the potential human, legal and other costs should a rope-related failure occur on the job. While some companies use serious accidents or near-misses as catalysts for change, today’s high-performing organizations are embracing preventive investment.

6. Administrative complexity. The prospect of navigating new standards can be daunting. Procurement and safety officers may feel burdened by the process of incorporating new specifications. But the fact is that today’s dielectric rope standards align well with existing safety frameworks used for FRP tools, insulating gloves and arc flash PPE.

Best Practices for Use and Maintenance
Whether your organization is already using dielectric ropes or still investigating their safety benefits, here are the best practices users and potential users should be aware of. In addition, always be sure to review and adhere to rope manufacturer instructions and guidelines.

1. Verify compliance with recognized standards.

• Ensure dielectric ropes fully comply with local governing standards and/or regulations.
• Request test reports and certification from rope suppliers that confirm lot traceability and leakage current performance.

 2. Store and maintain ropes like other insulating tools.

• Recondition dielectric ropes after use by placing them in a clean, well-ventilated, low-humidity room or trailer, avoiding exposure to contaminants.
• Thoroughly inspect, clean and test each rope between uses.
• Transport ropes in sealed containers or protective bags.

 3. Inspect ropes before each use.

• Visually inspect dielectric ropes for cuts, abrasions and dirt buildup. Damaged ropes must not be used.
• Perform periodic dielectric testing to ensure continued insulation.

4. Train workers.

• Educate crews about the risks of using non-dielectric ropes near energized or potentially energized systems.
• Provide workers with training on the specific dielectric ropes they will use, including handling protocols, which should be similar to those for hot sticks and FRP tools.

Conclusion
Assumptions that traditional synthetic ropes are nonconductive have been proven incorrect. Today, the electric utility industry is shifting toward the use of tested, standardized dielectric ropes. By adopting globally recognized standards, training employees on proper maintenance procedures and treating dielectric ropes as critical equipment, organizations can better prevent incidents, injuries and near-misses on their worksites.

About the Author: Patrick Barry is the vice president of commercial operations for Barry Cordage Ltd. He has 12 years of experience in the rope industry, with a specialized focus on utility and helicopter operations. Professionally certified by the Industrial Rope Access Trade Association, Barry has delivered global best practices training to operators in the commercial and military sectors. Recently, he has been a guest presenter for the EPRI Live Working Task Force and numerous public utilities, sharing insights on dielectric safety and innovative rigging solutions.