Often, you may come across an extension cord where the advertisement or packaging claims “OSHA Approved” or “Meets OSHA Requirements”, or something like these statements. The fact is, OSHA has no “approval”, per se for electrical extension cords, nor do they have a strictly defined “requirement” or “standard”.

According to OSHA Regulations (Standards – 29CFR) Use of Equipment – 1910.334:

“... Portable cord and plug connected equipment and flexible cord sets (extension cords) shall be visually inspected before use on any shift for external defects (such as loose parts, deformed and missing pins, or damage to outer jacket or insulation) and for evidence of possible internal damage (such as pinched or crushed outer jacket). Cord and plug connected equipment and flexible cord sets (extension cords) which remain connected once they are put in place and are not exposed to damage need not be visually inspected until they are relocated.”

“…If there is a defect or evidence of damage that might expose an employee to injury, the defective or damaged item shall be removed from service, and no employee may use it until repairs and tests necessary to render the equipment safe have been made.”

In a 1997 interpretation:

"Question #3:

Can electrical tape be used to cover minor nicks and abrasions in the outer jacket of a flexible cord? Under what circumstances, if any, may "electrical tape" be used to repair the outer cover of a flexible cord?

Reply:

Nicks and abrasions which do not penetrate completely through the outer jacket of a flexible cord are not considered a safety concern for which corrective action, that is, repair or replacement of the flexible cord, would be required. Repair or replacement of the flexible cord is required when the outer jacket is penetrated or the conductors or their insulation, inside are damaged. Flexible cord not less than No. 12 American Wire Gauge (AWG) may be repaired by splicing the conductors with a suitable vulcanized or molded splice. Please note that removing a damaged section of a flexible cord on an appliance and installing an attachment plug and a cord connection on the two ends would not be allowed. Such a repair would result in an extension cord between the flexible cord of the appliance and the installed building receptacle. Under paragraph 1910.305(a)(2)(i), this extension cord would be considered temporary wiring which is not permitted for workplace use.

Please note that flexible cord and cable should be visually inspected for external defects, such as insulation damage, and for indications of possible internal damage. Also, use of electrical tape to protect nicks or abrasions impedes visual inspection of the flexible cord. Flexible cords found damaged or defective must not be used until repaired.

We appreciate your interest in occupational safety and health. If we can be of further assistance, please contact the Office of General Industry Compliance Assistance [at (202) 693-1850]…"

Further interpretations have been made. See the OSHA web site at www.osha.gov.

In a strict sense, OSHA defines how an extension is to be used. OSHA also states that the extension cords be NRTL (UL and/or CSA) approved.

The bottom line is, if the cord is damaged, you may repair it under certain conditions, but do not use electrical tape to cover a nick or cut on the outer jacket. Use a cord that will be less likely to become cut, such as Northwire Contractor-Grade Extension Cords. Then, you will not be forced to throw out and replace so many extension cords at your job site.