If you think safety reminders about how to use an extension cord seem unnecessary, think again. Every year, workers are injured because damaged, overloaded, or improperly used extension cords create electrical hazards, fire hazards, and trip hazards. Even experienced employees can develop unsafe habits over time, which is why extension cord safety should be reinforced through regular safety meetings and toolbox talks.
Extension cords are found in construction, manufacturing, warehouses, offices, maintenance shops, and many other workplaces. Whether powering a drill on a job site or plugging in temporary office equipment, workers should understand how to inspect, use, and protect extension cords safely.
Extension Cords Are Temporary Power Sources
Extension cords are designed to provide temporary electrical power, not to replace permanent building wiring. Using extension cords improperly or leaving them in place for long periods can increase the risk of electrical shock, overheating, equipment damage, and fire.
No one should take electricity for granted. No matter how small the task, how temporary the project, or how experienced the worker, safe electrical work practices should always be followed.
OSHA Construction Standard 1926.416(a)(1) No employer shall permit an employee to work in such proximity to any part of an electric power circuit that the employee could contact the electric power circuit in the course of work, unless the employee is protected against electric shock by deenergizing the circuit and grounding it or by guarding it effectively by insulation or other means.
Construction sites are not the only places where extension cords create hazards. Office buildings, warehouses, manufacturing plants, schools, maintenance departments, and retail facilities all rely on temporary power from time to time. Employees in every work environment should understand the hazards associated with extension cords and know how to use them safely.
Choose the Right Extension Cord
Not every extension cord is designed for every application. Using an undersized or improperly rated cord can cause excessive heat buildup and damage to both the cord and the equipment being powered.
OSHA Construction Standard 1926.405(a)(2)(ii)(j) Extension cord sets used with portable electric tools and appliances shall be of three-wire type and shall be designed for hard or extra-hard usage. Flexible cords used with temporary and portable lights shall be designed for hard or extra-hard usage. Some examples include types SJ, SJO, SJT, SJTO.
Use Quality Extension Cords
Extension cords should be selected carefully and be approved by a laboratory such as Underwriters Laboratory (UL).
Always choose an extension cord with the proper length and electrical rating for the equipment being used. Avoid connecting multiple extension cords together unless absolutely necessary, as additional connections increase the potential for damage and electrical resistance.
Inspect Extension Cords Before Every Use
Damaged extension cords should never be used. Small defects can expose energized conductors and create serious shock or fire hazards.
OSHA General Industry Standard 1910.334(a)(2)(i) Portable cord and plug connected equipment and flexible cord sets (extension cords) shall be visually inspected before use on any shift for external defects (such as loose parts, deformed and missing pins, or damage to outer jacket or insulation) and for evidence of possible internal damage (such as pinched or crushed outer jacket). Cord and plug connected equipment and flexible cord sets (extension cords) which remain connected once they are put in place and are not exposed to damage need not be visually inspected until they are relocated.
Inspect extension cords for:
- Cuts, cracks, or frayed insulation
- Missing or broken ground pins
- Loose plugs or damaged connectors
- Burn marks or signs of overheating
- Crushed, pinched, or severely kinked cords
- Exposed wiring
Any damaged extension cord should be removed from service immediately and replaced.
Prevent Electrical and Trip Hazards
Improperly placed extension cords can create more than electrical hazards. Cords stretched across walking areas can cause slips, trips, and falls while also becoming damaged by foot traffic or equipment.
Cable protectors offer a quick solution to protect cables and hoses from pedestrian and vehicle traffic. Consider light- to medium-duty cable protectors to prevent trip hazards in an office or warehouse, while heavy-duty cable protectors might be a better choice on job sites with construction equipment or heavy pedestrian traffic.
OSHA General Industry Standard 1910.333(a) Safety-related work practices shall be employed to prevent electric shock or other injuries resulting from either direct or indirect electrical contacts, when work is performed near or on equipment or circuits which are or may be energized. The specific safety-related work practices shall be consistent with the nature and extent of the associated electrical hazards.
Protect Cords from Damage
OSHA Construction Standard 1926.405(a)(2)(ii)(l) Flexible cords and cables shall be protected from damage. Sharp corners and projections shall be avoided. Flexible cords and cables may pass through doorways or other pinch points, if protection is provided to avoid damage.
Never run extension cords where they can be crushed by vehicles, damaged by sharp edges, pinched in doors or windows, or exposed to excessive heat or standing water.
Safe Extension Cord Practices
During a weekly safety meeting or toolbox talk, workers should be reminded of these important extension cord safety tips:
- Always inspect your electrical tools and extension cords before use.
- Don’t use an extension cord that is wet and never plug an extension cord into an electrical device with wet hands.
- Never unplug an extension cord by pulling on the cord; pull on the plug only.
- Never use extension cords that have broken or missing ground pins.
- Use only properly rated extension cords for the work environment.
- Never run cords through windows or doors where they could be pinched or damaged.
- Ensure extension cords are kept out of walkways whenever possible to reduce trip hazards.
- Remove frayed, damaged, or severely kinked extension cords from use immediately.
OSHA General Industry Standard 1910.334(a)(5)(i) Employees’ hands may not be wet when plugging and unplugging flexible cords and cord and plug connected equipment, if energized equipment is involved.
Small Hazards Can Lead to Serious Injuries
Extension cords are one of the most common electrical items found in the workplace, yet they are often overlooked because they seem so familiar. Regular inspections, proper cord selection, good housekeeping, and safe work practices can help prevent electrical shock, fires, equipment damage, and trip hazards.
Taking a few extra moments to inspect and properly use an extension cord is a simple step that can help keep everyone working safely.
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