Dashpivot Article – Extension Cord Safety Tips
Extension Cord Safety Tips
Read on to learn about the most important extension cord safety tips, as well as how to share and apply these tips to improve extension cord safety.
Why is Extension Cord Safety Important?
Extension cords are everywhere in the modern workplace but we forget the risks. The US Consumer Product Safety Commission says 4,000 people go to the emergency room each year for extension cord injuries and 50 die annually from electrical fires caused by overloaded or damaged cords. This article is designed to provide you with some easy to apply but effective extension cord safety tips so that we can reduce the number of extension core safety incidents.
In industrial environments where power tools and heavy equipment are the norm, extension cords are a big deal. Extension cords are exposed to chemicals, extreme temperatures and mechanical damage from heavy equipment and foot traffic. Unless you have procedures and regular maintenance in place what was once a convenience can become a workplace hazard resulting in electrical fires, shock injuries and downtime at a big cost.
Why Extension Cord Safety Tips are Critical to Workplace Safety
In workplaces where power tools and equipment are used every day, extension cord safety can’t be overstated. Extension cords are used across many industries and are necessary for the safe and efficient operation of heavy machinery and tools.
But their convenience comes with a warning; if not used, maintained or stored properly they can be a hazard. These hazards can cause accidents like shock, fires and even death so it’s important to have strict procedures and awareness among all users.
Extension cords are pushed to the limit in industrial environments. They are stretched across long distances, run through high-traffic areas and exposed to extreme weather, oils, chemicals and abrasive surfaces.
These conditions can damage the cords in ways that aren’t visible to the human eye. This hidden damage can cause electrical faults which can stop operations and put people at risk. So regular inspection and maintenance of extension cords is key to detect and prevent these risks early.
And since extension cords are used in these workplaces you need to follow the safety standards and protocols. Make sure all cords are rated for the task and the environment they are used in to prevent overloading and electrical faults.
Train workers on extension cord usage - don’t daisy chain, don’t run them through water or doorways and make sure they are fully uncoiled to prevent heat build-up. So employees can make informed decisions about extension cord use and create a safety-first culture that protects people and the workplace.
Extension Cord Hazards
In workplaces where heavy machinery and equipment is used the safety of extension cords can be compromised by many factors. Knowing these risks is the first step to preventing the hazards and creating a safer workplace. Below are common extension cord safety risks that workers and management need to be aware of:
Misuse
Using extension cords for purposes beyond their design or electrical rating can cause overheating, short circuits and even fire. This includes using indoor-rated cords outdoors, exceeding the wattage rating or using a cord that has been damaged from previous misuse.
Physical Damage
Extension cords can get cut, abraded or crushed when run over by heavy equipment, pinched by doors and windows or stretched across sharp edges. Physical damage can expose wires and increase the risk of shock.
Environmental Exposure
Exposure to water, extreme temperatures, oils, chemicals and UV radiation can damage the insulation and overall integrity of extension cords making them unsafe to use.
Daisy-Chaining
Connecting multiple extension cords together or daisy chaining can cause voltage drops and overheating and is a serious fire and electrocution risk. It can also bypass the built-in safety features that protect against electrical overload.
Poor Storage
Cords that are not coiled, stored or hung properly can develop kinks, knots and bends that damage the internal wiring over time and hide dangers that may not be visible until failure occurs.
No Regular Inspection
Not conducting regular inspections and maintenance on extension cords can allow small damage to become a major hazard. Regular checks can identify and fix issues like fraying, cracking or other signs of wear before they become accidents.
Overloading and Overheating
Using extension cords for equipment that draws more power than the cord is designed for can cause overheating and start a fire. Using a coiled or poorly ventilated cord can trap heat and cause the same risk.
Ignoring Environmental Suitability
Not all extension cords are suitable for all environments. Using cords that are not rated for specific conditions such as wet areas or high-temperature areas can cause equipment failure and safety hazards.
Extension Cord Safety for Your Workers
Using extension cords safely in the workplace means following certain safety practices. Here are some practical tips for managing extension cords:
Extension Core Safety Tip - Choose the Right Cord
Select extension cords that are rated for the equipment’s power requirements and the environmental conditions. Choose cords with higher amperage and voltage ratings than the equipment and ensure they are certified for indoor or outdoor use as required.
Check extension cords for fraying, cracks or signs of wear on the insulation and ensure plugs and receptacles are intact and not damaged. Use a continuity tester to check for internal breaks or shorts and remove any faulty cords from service.
Use GFCI
Install Ground Fault Circuit Interrupters (GFCI) in all extension cord setups, especially in damp or wet areas. GFCIs detect an imbalance between the incoming and outgoing current and interrupt power quickly to prevent shock. Test GFCIs regularly to make sure they are working.
Don’t Overload
Never exceed the wattage rating of the extension cord. Add up the total wattage of all devices plugged into the cord and compare it to the cord’s rating which is usually in watts or amperes. Overloading can cause heat build-up and fire hazards.
Proper Placement
Route extension cords to avoid damage and tripping hazards. Use heavy-duty cord covers or secure cords away from high-traffic areas. Don’t pin cords to doors, windows or heavy objects that can damage the insulation and conductors.
Important Extension Cord Safety Tip - Keep Cords Uncoiled
Uncoil extension cords fully to allow heat to dissipate. Coiled cords can restrict current flow and generate excessive heat that can melt the insulation and cause fire.
Store Cords Correctly
Wind cords loosely to avoid kinks and store in a cool dry place away from direct sunlight and chemicals. Proper storage prevents insulation breakdown and cord structure damage.
Don’t Chain Cords
Don’t connect multiple extension cords together. Chaining can cause a big voltage drop to the equipment and increase the risk of overheating. Use one longer extension cord that can handle the load safely.
Follow the Manufacturer’s Guidelines
Follow the manufacturer’s guidelines for extension cord use. This includes load capacity, environmental limits and specific maintenance and safety checks.
How to Share Extension Cord Safety Tips to the Workplace
Extension cord safety tips must be shared with workers to keep the work area safe. Here’s how:
Extension Cord Safety Tips via Training Sessions
Have regular safety training sessions that are mandatory for all employees. These sessions should cover electrical safety, extension cord use and the above safety tips. Include interactive elements like quizzes or hands-on demonstrations to engage workers and reinforce learning. Use technical examples to explain the consequences of misuse like overloading cords or using damaged cords.
Extension Cord Safety Tips via Visual Aids
Post visual aids like posters and signs in areas where extension cords are used. These should highlight extension cord safety tips like inspecting cords before use and storing cords properly. Visual aids are constant reminders and can be effective in high-traffic areas. Make sure the materials are designed with clear and easy-to-understand graphics that can convey the message at a glance.
Digital Resources
Use digital platforms like the company intranet, email newsletters and SMS to share extension cord safety tips. Create short and snappy content like videos, infographics or quick tips that workers can access on their mobile devices. This way you can reach a large audience quickly and can update the information regularly to reflect new safety standards or practices.
Toolbox Talks
A toolbox talk is an informal chat on a specific safety topic like extension cord safety. It’s a direct conversation between supervisors and their teams and a great opportunity to discuss safety practices, share stories and clarify questions.
To do a toolbox talk on extension cord safety prepare a quick outline that covers the points like choosing the right cord, inspection techniques and usage practices. Ask workers about their experiences and challenges with extension cords.
Use real-life examples or case studies to explain the risks and why we need to follow the safety protocols. Keep the session interactive and ask questions to make sure the information is understood and retained. We want to create a safety culture where workers feel responsible for extension cords.
Safety Audits and Feedback Sessions
Do regular safety audits and document safety audit checklists to check extension cord practices. After the audit have a feedback session with workers to discuss the findings and address their concerns.
So we not only identify the risks but get workers to be part of the solution. Ask employees how extension cord safety can be improved and make a team where everyone is responsible for workplace safety.
Note the actions for extension cord safety. Extension cord safety will be a topic again. Ever. So you’ll have to do this again.
Here’s an example of an extension cord safety toolbox talk that has been recorded using a topic-specific toolbox talk form:
Free Toolbox Talk - Extension Cord Safety Template
Use this form to share extension cord safety tips in your workplace
Pass these extension cord safety tips onto your workers more easily
Teaching your team extension cord safety is easier than other safety topics because following extension cord safety procedures doesn’t require a lot of technical knowledge. Running a focused toolbox talk when extension cords are being used heavily is one of the best ways to do extension cord safety.
Use this extension cord safety toolbox talk template for your next toolbox talk. It’s pre-filled with all the fields and sections you need to do a toolbox talk on extension cord safety.
You can record all your discussion points, add extra notes from team members, assign tasks and record attendance in one form. You can also upload files to the form like extension cord safety images and photos.
Electrical safety audit checklist template
Conduct and complete electrical safety audit checklist easily, to keep your people safe and your records compliant.
Cable Inspection Checklist template
Keep all of your power and electrical cables in good and safe 'hands' by properly inspecting your cables with this checklist.
Safe Work Method Statement for Power Tools template
Power tools pose a constant hazard and risk to many workers. Ensure everyone is using and managing power tools properly with a good SWMS.
Sitemate builds best in class tools for built world companies.
English (United States) 
English (Australia) 
English (UK) 
English (New Zealand) 
English (South Africa) 
German