ISSUES:
Extension cords are a leading cause of electrocution fatalities on construction sites.
Extension cords are a major contributing factor in fall-related incidents.
Improper use—such as damaged insulation, missing prongs, or indoor-rated cords used in wet conditions—can cause shocks, burns, or fires.
Many electrical fatalities can be prevented through daily inspections and proper equipment, including GFCI protection and grounding.
THE FACTS: ALL THESE ISSUES ARE AVOIDABLE IF:
- Inspected: Extension cords and flexible cord sets must be visually inspected for defects such as damaged jackets, missing pins, or signs of internal damage before each use.
- Removed if Damaged: Any cord with defects or damage that could expose an employee to injury must be taken out of service immediately and not used until repaired and tested by a qualified professional.
- Correct Type and Gauge Is Used:
- a. Cords must be rated for the equipment and match voltage and amperage requirements.
- b. Cords must be the correct gauge for the cord length and electrical load to prevent overheating.
- c. Construction extension cords must be 3-wire type to provide proper grounding.
- Only Used for Temporary Use: Extension cords are for temporary use only and cannot be substituted for permanent wiring or attached to building surfaces.Cord Protection Is Mandatory: Cords should be protected from damage caused by foot traffic, equipment, or any other hazards.
- Environmental Elements Are Identified: Do not use electrical equipment, including extension cords, in wet or damp locations.
- No Splices Are Allowed: Flexible cords should be used in continuous lengths without splices. Manufacturers recommend not using two extension cords plugged into each other.
- GFCI Protection Is Mandatory: In wet or damp conditions, cords must be plugged into Ground Fault Circuit Interrupter (GFCI) outlets to protect against electrical leakage and shock.
COMMON CAUSES OF EXTENSION CORD ACCIDENTS:
- Not using hard-usage rated cords:
The Occupational Safety and Health Administration (OSHA) requires cords rated for hard or extra-hard usage on construction sites. - Not inspecting cords regularly:
Always check cords for damage before each use. Do not use a cord that has cut or damaged insulation, missing ground plugs, or signs of stress. - Not ensuring proper grounding:
Never remove ground prongs and always use three-prong plugs in three-prong outlets. Do not use adapters to force a three-prong plug into a two-prong outlet. - Not using GFCI-protected cords:
Ground Fault Circuit Interrupters (GFCIs) provide an extra layer of protection by shutting off power in the event of a fault, which can prevent electrocution. - Not managing cords properly:
Keep cords away from doorways, walkways, and areas where they can be pinched or damaged. Never run cords under carpets or through walls. - Not using cords as permanent wiring:
Extension cords should only be used for temporary purposes.
CONSEQUENCES OF CONSTRUCTION EXTENSION CORD HAZARDS:
- Injuries and fatalities
- Project delays
- Legal and financial repercussions
SOURCES OF EXTENSION CORD HAZARDS:
- Damaged insulation: Electrical conductors can become exposed from cuts, abrasions, or aging, which can cause shocks and fires.
- Improper grounding: Removing ground prongs or using adapters to bypass grounding devices can create a direct path for electricity to flow through a worker.
- Improper use in wet conditions: Using cords not rated for outdoor or wet environments can cause current leakage and shock if connectors or tools get wet.
- Tripping hazards: Loose and exposed cords are a major cause of slips, trips, and falls, which can result in serious injury or death.
- Overloading: Using cords that are not the correct size or rating for the equipment can cause overheating and fires.
REGULATIONS:
- OSHA Standard Subpart E – Electrical – 1926.404(b)(1)(iii)(C): Each cord set, plug, and connected equipment shall be visually inspected before each day’s use for defects such as damaged insulation or missing pins. Any damaged or defective equipment must be removed from service until repaired.
- OSHA Standard Subpart K – Electrical – 1926.403(b)(2): Listed, labeled, or certified equipment shall be installed and used in accordance with instructions included in the listing, labeling, or certification.
- OSHA Standard Subpart K – Electrical – 1926.405(j)(1)(i): Fixtures, lampholders, lamps, rosettes, and receptacles shall have no live parts normally exposed to employee contact.
- OSHA Standard Subpart K – Electrical – 1926.404(b)(1)(i): Employers shall use either ground fault circuit interrupters or an assured equipment grounding conductor program to protect employees on construction sites.
- OSHA Standard Subpart K – Electrical – 1926.403(b)(1): Employers shall ensure that electrical equipment is free from recognized hazards likely to cause death or serious physical harm.
- OSHA Standard Subpart K – Electrical – 1926.405(a)(2)(ii): Feeders shall originate in a distribution center and be run as multiconductor cord or cable assemblies, within raceways, or as open conductors when protected.
- OSHA Standard Subpart K – Electrical – 1926.405(a)(2)(ii)(I): Flexible cords and cables shall be protected from damage. Sharp corners and projections shall be avoided.
WHAT YOU NEED TO KNOW! ACTION STEPS FOR CONTROLLING EXTENSION CORD HAZARDS (DO):
- Do visually inspect cords for defects daily and before each shift.
- Do remove all damaged cords from service.
- Do protect cords from damage caused by foot traffic, equipment, or other hazards.
- Do use the correct type and gauge of cord.
- Do require permanent wiring for extended use.
- Do use GFCI protection at all times and double-check in wet or damp conditions.
- Do avoid using extension cords in wet areas as much as possible.
- Do use flexible cords in continuous lengths and the correct length for the application.
- Do practice proper extension cord management and store unused cords properly.
ACTION STEPS FOR CONTROLLING EXTENSION CORD HAZARDS (DON’T):
- Don’t use electrical equipment, including extension cords, in wet or damp locations unless protected with GFCIs and grounding. Never plug two cords together in wet locations.
- Don’t ignore any defects in extension cords (cuts, missing ground pins, signs of stress relief failure).
- Don’t use extension cords where their integrity can be compromised (rough surfaces, steel tracks, sharp stones, or sharp edges).
- Don’t use extension cords where equipment, scaffolding, or carts must pass over them.
- Don’t use extension cords for permanent use (OSHA defines this as longer than one day or shift).
- Don’t use any cord rated less than 12 gauge.
