08 Aug Electrical Cord Repair Safety – Is It OK to Repair Electrical Cords?

Electrical Cord Repair Safety – Is It OK to Repair Electrical Cords?

Electrical cord repair safety requires knowing when a damaged extension or equipment cord may legally and safely be repaired—and when it must simply be removed from service.

Improper repairs can create serious shock, electrocution, fire, and equipment hazards. Electrical tape, makeshift splices, and improvised plugs do not automatically make a damaged cord safe.

Can a Damaged Cord Be Repaired?

It depends on the type and size of the cord.

Under Federal OSHA construction requirements, flexible cords generally must be used in continuous lengths without splices or taps. Hard-service flexible cords No. 12 AWG or larger may be repaired only if the splice restores the insulation, outer sheath properties, and usage characteristics of the original cord.

For general industry, OSHA allows repair of hard-service and junior hard-service cords No. 14 AWG or larger when the repaired splice retains equivalent insulation, outer sheath, and usage characteristics.

Because construction rules are more restrictive, employees should follow the applicable company electrical-safety procedure and never assume that any damaged cord can be repaired.

Do Not Use Tape as a Makeshift Repair

Wrapping a worn, cut, or frayed extension cord with electrical tape is generally not an acceptable way to restore a damaged cord. OSHA has specifically noted that taped repairs usually do not restore the original jacket’s strength, flexibility, or protective characteristics.

If the cord jacket is damaged enough that its protective properties have been compromised:

• Remove the cord from service.
• Tag it to prevent accidental use.
• Have it evaluated by a qualified person.
• Replace it or repair it only when the applicable OSHA requirements and manufacturer instructions permit the repair.

Do not use duct tape or other makeshift materials to return a damaged electrical cord to service.

Splices

Where a splice is permitted, it must restore the cord to a condition equivalent to its original construction and intended use.

A proper repair must preserve:

• Conductor insulation.
• Outer jacket or sheath protection.
• Flexibility.
• Mechanical strength.
• Grounding continuity.
• Strain resistance.
• Suitability for the environment in which the cord will be used.

A simple twisted-and-soldered connection covered with shrink tubing or tape should not automatically be considered an OSHA-compliant repair. Construction cords smaller than No. 12 AWG generally may not be repaired by splicing at all.

Replacement Plugs and Connectors

Damaged attachment plugs or cord connectors may sometimes be replaced when the repair is permitted and performed correctly.

When replacing a plug:

• Disconnect the cord from all electrical power before beginning.
• Use a replacement plug rated for the cord and intended environment.
• Maintain correct conductor identification and grounding.
• Secure terminal connections properly.
• Ensure the cord’s outer jacket is captured by the plug’s strain-relief device.
• Never allow pulling force on the cord to be transmitted directly to terminal screws or conductor connections.

OSHA requires flexible cords to be connected to fittings so that adequate strain relief prevents pull from being transmitted directly to the joints or terminal screws.

Inspect Before Use

Before using an extension cord or cord-connected tool, check for:

• Cuts, cracks, or worn insulation.
• Exposed conductors.
• Missing or damaged grounding pins.
• Loose or damaged plugs and connectors.
• Burn marks, melted insulation, or evidence of overheating.
• Improper splices or taped repairs.
• Damaged strain relief.
• Crushed or flattened sections.
• Other conditions that could affect safe operation.

Remove defective cords from service immediately.

Testing After Repair

Where a repair is permitted, the cord should be inspected and appropriately tested before being returned to service. Testing should verify, as applicable:

• Electrical continuity.
• Equipment-grounding conductor continuity.
• Correct polarity.
• Absence of shorts or improper connections.
• Proper operation of the repaired cord or equipment.

Testing should be performed by a person qualified and authorized under company procedures.

Remember

Electrical cord repair safety means recognizing that not every damaged cord can or should be repaired. Never rely on tape or an improvised splice. Remove damaged cords from service and repair them only when the cord type, OSHA requirements, manufacturer instructions, and company procedures permit it.