fast facts 

Damaged Power Cords: 

Know your electrical supply cord 

July 2009 

Office of Compliance 

advancing safety, health, and workplace rights in the legislative branch 

www.compliance.gov 

 Power cords on electrical appliances that are moved frequently receive a lot of abuse. These include 

vacuum cleaners, floor polishers, power tools and other portable appliances. Often, the damage occurs at the 

plug (i.e., a missing ground prong on a three pronged grounded plug - Figure 1). Damaged and ungrounded 

power cords pose serious hazards to users of the appliance including electrical shock and risk of fire. Missing 

ground prongs on power cord plugs usually result from users pulling on the cord to remove the plug from the 

outlet instead of handling the plug directly. In some cases, the plug may be pulled from the wire covering, 

exposing the inner wires to damage, as shown in Figures 2 and 3. Power cords can become frayed or damaged 

from heavy use, age, or excessive current flow through the wiring. 

Figure 4 shows a power cord to a shop appliance that was found on a recent inspection. This power 

cord has been sliced open exposing the inner energized wires. The appliance was still plugged in, ready for use. 

When a power cord is damaged, the appliance should be removed from service and the cord replaced as soon as 

possible to reduce the risk of electrical shock, electrocution or fire. 

Cord damage can also result when the cord is pinched, caught between or punctured by heavy objects 

such as legs on a desk. This damage could lead to a short circuit and result in a fire. Also, cords placed under 

stress, such as when a heavy appliance is hung by its cord, could eventually cause damage to the cord or plug. 

For greater detail on power cords, please see Fast Facts on “Power Strips and Daisy Chains” and 

“Exposed Energized Wiring,” available on our website, www.compliance.gov. 

Figure 1 Ground prong 

broken off 

Figure 2 Wire Cover 

pulled from plug 

Figure 3 Plug pulled from casing & 

insulation 

Figure 4 Frayed cord exposing energized wires 
 fast stats 

• OSHA 29CFR§1910.303(a) states that electrical powered equipment must be approved in the manner prescribed by OSHA 

and one of its recognized testing laboratories. OSHA 29CFR§1910.334(a)(3)(ii) requires that attachment plugs and receptacles may not be connected or altered in a manner which would prevent proper continuity of the equipment grounding conductor. Further, 29CFR§1910.334(a)(2)(ii) provides that if there is a defect or evidence of damage to electrically powered 

equipment, 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. 

• The National Fire Protection Association’s (NFPA) National Electrical Code, NFPA 70 section 250-114 states that equipment powered by cords and plugs with exposed non-current carrying metal parts likely to become energized shall be 

 grounded for various listed appliances, and if an appliance has a ground prong on its power cord plug, it must not be 

 removed. Continuing use of appliances with damaged power cords is a violation of the National Electrical Code, NFPA 70 

 in sections 110-2, 110-3(a) and (b), 110-27(a), and 250-2(b)-(d). 

 

• The NFPA reported that in 2008, electrical fires, electrical failures or malfunctions resulted in an average of 53,600 home 

fires each year. These fires caused more than 500 deaths, injured 1,400 people, and accounted for $1.4 billion in property 

damage. 

• The Bureau of Labor Statistics of the U.S. Department of Labor reported that in 2007, private sector workers suffered 1,100 

electrical burn injuries and 1,480 electrical shock injuries. 

 

This information does not constitute advice or an official ruling of the Office of Compliance or the Board of 

Directors and is intended for educational purposes only. For further information or comments concerning this 

Fast Facts, please refer to the Congressional Accountability Act (2 U.S.C. 1301 et seq.) and the regulations 

issued by the Board, or you may contact the Office of Compliance, 202-724-9249.

The Office of Compliance advances safety, 

health, and workplace rights in the U.S. 

Congress and the Legislative Branch. Established as an independent agency by the 

Congressional Accountability Act of 1995, 

the Office educates employees and employing offices about their rights and responsibilities under the Act, provides an impartial 

dispute resolution process, and investigates 

and remedies violations of the Act. 

If you have any questions, please do not 

hesitate to contact the Office of Compliance: 

Room LA 200, John Adams Building 

110 Second Street, SE 

Washington, D.C. 20540 

t/ 202-724-9250 

tdd/ 202-426-1912 

f/ 202-426-1913 

Peter Ames Eveleth 

General Counsel 

Mary-Margaret Smith 

Editor 

Download the entire Fast Facts suite at http://www.compliance.gov 

Power Cord Safety 

 Power cords are generally made up of three layers. The innermost layer is composed of two copper wires 

used to carry an electrical current to an appliance together with the ground wire. Next, the insulation layer 

directly covers the wiring to protect it from damage and short circuits or electrical faults. Lastly, the outer layer, 

consists of rubber or plastic that is molded around the wires, and of insulation for further protection from mechanical damage and wear. Each electrical appliance power cord is evaluated by an electrical testing laboratory. 

Samples are tested to verify that the cord is safe for normal use when following the manufacturer’s instructions. 

The testing laboratory issues an approval or listing of the cord indicating that it meets applicable requirements. 

The Occupational Safety and Health Administration (OSHA) requires all electrical equipment over 50 volts be 

approved by a recognized testing laboratory. It is incumbent upon the user to make certain that the power cord 

remains in serviceable condition. 

The Office of Compliance has found many damaged power cords during its inspection work and recommends that users of the electrical tool or appliance inspect the power cord before and after each use. This could 

help prevent a personal injury or fire.