Extension Cord Repair
Extension Cord Repair - what repairs are permissible?
I know you can use electrical tape for superficial damage, but looking for clarification on more in-depth repair.
Extension cords used in construction may be repaired, so long as the repair returns the cord to the "approved" state required by §1926.403(a).
This section states, "All electrical conductors and equipment shall be approved."
The repair of cords and cord sets is permitted under 1926.404(b)(1)(iii)(C):
Each cord set, attachment cap, plug and receptacle of cord sets, and any equipment connected by cord and plug, except cord sets and receptacles which are fixed and not exposed to damage, shall be visually inspected before each day's use for external defects, such as deformed or missing pins or insulation damage, and for indications for possible internal damage. Equipment found damaged or defective shall not be used until repaired. (Emphasis added.)
Repairs of extension cords are therefore permitted under §1926.404(b)(1)(iii)(C). However, in order to remain compliant with §1926.403(a), the repairs must return the equipment to the state in which it was initially approved.
Similar repairs are discussed in our May 19, 2003 letter to Barry Cole:
To satisfy the requirements of the OSHA standards, a repair would have to restore the tool to its "approved" condition in accordance with §1926.403(a). Tools ... are approved as complete factory-produced entities. The approval is for the tool as a whole - its design, capacity, materials and construction. This provision precludes the use of an approved tool if its characteristics are materially altered.
Also, what about general industry?
Comments (10)
We would only authorize repairs by an electrician who used the same size and type of wire and plug. 3 prong for 3 prong, 2 prong for 2 prong, etc. and all repairs had to be properly insulated and shrink wrapped after they were tested to ensure a proper repair. In other words returned to as close to new as is possible.
Don’t do it! Cords aren’t that expensive.
I’ve found that in virtually all industries an electrician needs to make the repair. This is one of those areas where I think the law is too restrictive. Cord and plug ends are easily repairable and it is just flat out wasteful to throw away what would be a safe, functioning cord with a simple repair.
We are losing fundamental skills on the job and it’s just sad to see this.
Personally, I'd just buy a new one. I feel like even making repairs is a temporary measure
I am not a "Construction" expert so feel I should only comment on General Industry and Manufacturing. In my world my advice is to, "Just do not open that can of worms!" If a cord is damaged it is cut into several pieces (so someone cannot take it home and use it, and you are liable) and a new one is brought out! We keep several in the Tool Crib! It is just not worth the risk. Our policies were supposed to SURPASS OSHA regs. My former corporation had a Corporate EHS Policy that banned even having electrical tape in our plants and its use! I use to have to fight the Maintenance Manager, Supervisor, and Electricians on that one all the time! We also had controls on Extension cords for "temp use only", all had to have UL labels (no homemade here), and GFCI's mandatory on all ext cords! Good luck! Extension Cords are hard to control!
Really good question!! Thanks B!
Hey! I know Barry Cole! I love when I read an osha interpretation letter and know the requestor!
Some states, unions, sites etc have rules about these repairs beyond osha. I usually have erred on the side of caution and had the cord replaced.
All repairs have to be done by a qualified person (which doesn't always mean they have to be an electrician, but that is one type of qualified person) and returned to it's original condition. If you're repairing it, you need to get replacement/repair parts that are rated for the same voltage, amps, resistance, etc., it's the same size (AWG), has the same number of prongs if it's a cord end, etc. Some cords are cheaper than others, though. An indoor cord that only cost around $10-$20 is one thing, but a 75+ ft. heavy-duty GFCI cord rated for outdoor use can run upwards of $100 each, so that gets a little pricey. However, sometimes you have to destroy them.
Electrical tape can only be used in certain situations. If you're using it to cover up cuts in the insulation/cord jacket that's down the bare wire, then that's not acceptable. If you're using it to prevent chaffing and damage while it's going underneath, through, or otherwise around something with a sharp edge, then that's acceptable. It "can" also be used if it's just superficial nicks in the insulation/cord jacket (meaning no bare wires are exposed), but it's not recommended by OSHA (see this letter of interpretation -
https://www.osha.gov/laws-regs/standardinterpretations/1998-12-16
)
OSHA's construction industry also specifies the size wire that can be repaired (#12 AWG, shown below).
1926.405(g)(2)(iii)
Splices. Flexible cords shall be used only in continuous lengths without splice or tap. Hard service flexible cords No. 12 or larger may be repaired if spliced so that the splice retains the insulation, outer sheath properties, and usage characteristics of the cord being spliced.
As Abby mentioned, always consult with your local and state regulations because they may be more stringent than OSHA.