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“Extension Cord Roulette — Damaged Cords, Grounding, and Overload” On most jobsites, extension cords are so common we barely notice them. They’re everywhere—running across floors, through doorways, over scaffolds, and around equipment. And that’s exactly why they’re dangerous. We treat extension cords like harmless accessories, when in reality, they’re temporary power lines. And every time you plug one in, you’re taking a chance—unless you know it’s safe. That’s why today’s message is simple: Using damaged or overloaded cords is like playing roulette with electricity. A Real Jobsite Story A worker grabbed an extension cord that had a small nick in the insulation. Nothing major. It had “worked fine all week.” The floor was damp from morning cleanup. When he plugged in a grinder, the exposed conductor contacted moisture. The current traveled through the wet surface and into his body. He was knocked to the ground by the shock and suffered severe burns to his hand. One small cut in insulation. One wet surface. One bad outcome. Why Extension Cords Are So Dangerous Extension cords aren’t designed for permanent use. They get: • Crushed by equipment • Cut by sharp edges • Pinched in doors • Worn from foot traffic • Stretched beyond their rating Inside that outer jacket are live conductors. When insulation is damaged, electricity looks for a new path—and that path might be you. Add in water, sweat, or metal surfaces, and the risk goes up fast. The Three Big Hazards 1. Damaged Cords Cracks, cuts, exposed wires, loose plugs—any of these can energize the outside of the cord or the tool. 2. Missing or Defeated Grounding The ground prong exists to protect you. Removing it doesn’t fix a problem—it creates one. 3. Overloading Plugging too many tools into one cord or one outlet overheats wires and can start fires or cause insulation failure. Electricity doesn’t care that you’re “just trying to get the job done.” How to Use Extension Cords Safely 1. Inspect Before You Plug In If it’s cut, cracked, spliced, or missing a ground—tag it and remove it. 2. Use the Right Cord for the Job Match the cord rating to the tool and the environment. Heavy tools need heavy-duty cords. 3. Keep Cords Out of Water and Traffic Elevate them when possible and protect them from damage. 4. Never Defeat the Ground That third prong is there to save your life. 5. Don’t Overload Circuits Use proper power distribution and GFCI protection. Dangerous Habits That Get People Hurt • Using cords with taped repairs • Cutting off ground prongs to “make it fit” • Daisy-chaining multiple cords and power strips • Running cords through water or mud • Assuming “low voltage” means low risk • Leaving damaged cords in service Most electrical shocks from cords come from small problems that were ignored. Supervisor Note Supervisors must: • Enforce daily cord inspections • Remove damaged cords from service immediately • Ensure proper GFCI and grounding protection • Provide the right cords for the tools being used • Never allow temporary wiring to become permanent If a cord isn’t safe, the tool doesn’t get used. Closing Extension cords don’t look dangerous. But they carry the same electricity as the power in the wall. One cut. One missing ground. One overloaded line. That’s all it takes. So inspect before you plug in. Use the right cord. And never gamble with temporary power. Because when electricity finds a shortcut… it usually goes through you.