Electrical workers depend on tools and equipment every day. Corded and battery-powered tools, extension cords, voltage testers, temporary lighting, insulating equipment and personal protective equipment are used so routinely that their condition is often taken for granted. However, a damaged tool or worn piece of equipment can turn an ordinary task into a serious incident. Several tactics can be used to mitigate these risks.

Equipment conditions

Danger is not limited to a tool’s complete failure. A cracked housing, loose connection, missing ground prong, worn cord, damaged guard or contaminated insulating surface can expose a worker to shock, arc flash, burns, cuts, falls or fire. These defects can be made worse by wet conditions, conductive surfaces, confined spaces and other demanding environments found on job sites.

Workers must treat equipment condition as a central part of electrical safety. They should not assume a tool is safe because it operated correctly the previous day. Most job site tools are exposed to conditions that accelerate wear, as they are transported in trucks, dropped from ladders, dragged across concrete, exposed to heat and moisture, and stored alongside heavy materials. 

The gradual nature of this deterioration is part of the problem. A worker may continue using a cord with a small abrasion because the copper is not yet visible. A cracked drill housing may be overlooked because the tool still runs. However, over time vibration, moisture, heat and continued handling can expand a minor defect into a dangerous failure.

OSHA notes that flexible cords can be damaged by door and window edges, staples and fasteners, abrasion from surrounding materials or simply through aging. When internal conductors become exposed, that can result in electrical shock, burns or fire. Extension cords and cord-connected tools are among the most frequently damaged items on electrical job sites. OSHA requires portable cord-and-plug-­connected equipment and extension cords to be visually inspected before use on each shift for defects, such as loose parts, missing or deformed pins, damaged insulation or crushed/pinched jackets. Equipment showing damage must be tagged and removed from service. 

Missing grounding prongs are another common hazard. Workers should never accept a missing ground pin or use an improvised adapter to keep equipment operating.

One of the most persistent job site problems is the temporary repair that becomes permanent. Electrical tape may be wrapped around a damaged cord, a guard may be wired open or a broken plug may be positioned so it continues to make contact. These repairs can hide defects rather than correct them. OSHA has warned that wrapping electrical tape around worn or frayed flexible cord does not necessarily restore the cord to its originally approved condition. 

Damaged tools also present mechanical risks. Missing guards, defective triggers, worn blades, loose handles and damaged battery housings can cause lacerations, struck-by injuries, fires or unexpected startup. For example, a drill with a sticking trigger may continue operating after the worker releases it.  

Damaged test equipment is especially dangerous because it may produce an incorrect reading and lead a worker to believe equipment has been de-energized. Meters, probes, leads and voltage detectors should be inspected for cracked housings, damaged insulation, exposed conductors, loose connections and correct ratings. A damaged meter lead may expose the user directly to voltage. (To learn more about how to care for meters, turn to Cool Tools on page 56.)

Additionally, the condition of larger electrical equipment also directly affects worker safety. Corrosion, contamination, overheating, loose components, damaged insulation and missing covers can increase the likelihood of shock or arc-flash incidents. OSHA requires electrical equipment to be free of damage that may adversely affect safe operation or mechanical strength. 

Be sure to give attention to rubber-­insulating gloves, sleeves, blankets, line hose, hot sticks and other insulating protective equipment. Contamination, cracking, punctures, tracking, moisture and improper storage can reduce their protective value. OSHA requires live-line tools used as primary protection to be regularly examined, cleaned and tested or removed from service according to established intervals and conditions.

Build an inspection program

The best way to combat all these issues is for employers to build a strong inspection program. Workers should do pre-use inspections, and supervisors must immediately address reported defects. Employers should also schedule more detailed periodic inspections based on manufacturer recommendations, job site conditions, frequency of use and equipment history. An effective program should address power tools and battery packs, extension cords and temporary power, test instruments and leads, ladders and aerial equipment, insulating gloves and protective equipment, ground-fault circuit interrupters, guards and safety switches. Training should include examples of acceptable and unacceptable conditions. 

Employers should also have clear repair procedures. Workers need to know who is authorized to repair tools, how defective equipment should be identified and where it should be placed so another employee does not unknowingly return it to service. 

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