Tips for Using Industrial Extension Cords

Extension cords can be handy when you don’t have convenient outlets. They can also be helpful when using machines with short cables that can’t reach nearby electrical outlets. But not all extension cords are the same. Choosing the right extension cord is essential to ensure electrical safety and prevent fire hazards.

Most people assume the extension cord is heavy-duty simply because it is long and orange or yellow. However, there is more to extension cords than length and color. Just because a particular extension cord is attractive doesn't necessarily mean it fits the job. For instance, it has to have the right amperage rating for use with your device or handle a particular job.

A heavy-duty industrial extension cord will get the job done when working with power tools for industrial or commercial environments.

Here are some tips to help you keep safe when using an extension cord:

Crucial Tips You Need to Know Before Using an Industrial Extension Cord

Do You Require Indoor or Outdoor Extension Cords?

Extension cords can either be for outdoor or indoor use. There are many differences between the two besides where they are meant to be used. For example, an outdoor-rated extension cord uses tough material for insulation and withstands severe outdoor conditions like temperature changes, UV rays, moisture, and sometimes exposure to chemicals.

While using an outdoor extension cord for an inside task is possible, it is dangerous to use an indoor-rated extension cord outside as it can cause electric shock or fire hazards. So, use the right extension cords in the right environment.

Consider Gauge, Distance, and Wattage Rating

Every extension cord comprises an inner metal conducting wire, transmitting current from one end to another. Gauge is the thickness of the conducting wire, denoted by a number. The lower the figure, the thicker the wire. The thickness of a wire indicates the amount of current a wire can carry over a specific distance.

Consequently, wattage rating indicates the wattage amount an extension cord can safely transmit depending on its length and gauge. Before you plug equipment into an extension cord, it is crucial to ensure that the device’s power demand does not exceed the cord’s wattage rating.

When powering multiple machines using a single extension cord, consider calculating their combined energy demand to ensure it does not exceed the cord’s wattage rating. If you supply more power than it is rated for, the cord will overheat, potentially causing accidents.

Choose the Right Extension Cord for Your Needs

There are three broad categories of extension cords: frequent use, occasional use, and rugged use. When buying an extension cord, check these designation letters on the package or the cord itself to make sure it is the right type:

• S- General-use cord appropriate for indoor applications.
• O- Oil-resistant.

• P- A household cord with parallel wire construction.
• W- For outdoor use. The significant difference between outdoor and indoor extensions is the insulation. Outdoor cords have an orange rubber, plastic, or vinyl cover, while indoor extension cords are less heavy-duty.
• T- Cord insulation is made of vinyl thermoplastic.
• J- Cord has standard 300-volt insulation. If the cord has no designation J, it is designed for heavier use with 600-volt insulation.
• E- Cord insulation is made of thermoplastic elastomer rubber (TPE).

Buy Three-Prong Plug Extension Cords

Standard extension cords are either with two or three prongs. One prong is live while the other is neutral, while the third prong is a path to the ground wire. The third prong serves a crucial purpose as it significantly reduces the risk of electrical shocks and fire hazards by providing power surges a safe path to dissipate.

You can use three-prong extension cords with three-prong power outlets. However, if your home has old electrical wiring, you may need to make an upgrade before you convert your outlets to newer three-prong versions designed to improve electrical safety.

Avoid Overloading Your Extension Cords

Every extension cord has a maximum amperage rating or a limited amount of electrical current that it can safely transmit. Check the appliance you want to connect and choose an extension cord with an amperage rating more significant than the devices.

If you connect multiple electronics, add up all their amperage requirements to avoid overloading the cord. If the power that the device needs is indicated in watts, divide the wattage by 110 to convert the rating to amps.

Sometimes the cord manufacturers fail to indicate the amperage rating on the cord. If it's missing, calculate its current capacity using its gauge. The lower the gauge, the higher the current capacity. Here are the standard uses:

• 16-gauge: For light-duty applications like holiday lights and portable fans.
• 14-gauge: For medium-duty applications such as lawnmowers and power drills.
• 10 to 12-gauge: For heavy and extra heavy-duty applications like chainsaws and air compressors.

You can also use its length to choose the right type of cord that suits your needs. More extended codes have more electrical resistance and less power to the connected appliance. So, use power cords with the right length to minimize current loss, especially when powering a higher amperage device.

Avoid Plugging Sensitive Appliances into Regular Extension Cords

Many people think extension cords and surge protectors serve the same purpose. However, surge protectors block or divert excess power by grounding it. Even minor surges can cause severe damages to the appliances. Always plug the extension cord into a surge protector or use a cord with built-in surge protection.

Don’t Cover the Cords

You might be tempted to place the extension cords under the carpet as a way of keeping them out of sight. But it isn't the best idea as running it under the rugs will block the cord from releasing heat. Consequently, build-up heat close to flammable material may cause a fire outbreak.

Instead, running the extension cords alongside the wall may be effective. The goal is to prevent overheating while keeping everyone safe by avoiding tripping, trapping it under truck wheels, or getting it stomped on mud. Apart from keeping the working area safe, it ensures durability with nothing walking over or crushing it.

Keep Away from Foot Traffic

Keeping power cords out of places where people typically walk in is something that people do to keep and maintain a better appearance in the property. This will also prevent the cord from getting bent.

Always keep extension cords away from places where they can easily be pulled down to prevent fire hazards and keep the working environment safe.

Be Careful of Overheating

Any electrical appliances that you buy will likely come with warnings of flammability and safety precautions you should take. This will ensure your safety and safeguard the condition of your machine.

The easiest way to avoid overheating is by not overloading the cord and unplugging it from the power source when it becomes hot.

Avoid Using Multiple Extension Cords

Similar to overloading an extension cord, plugging several cords into one another can be risky since they exceed the allowed power transmission. Overloading the extension cord is one of the leading causes of workplace fires. If you must use extension cords for appliances that drain a lot of power in your operations, ensure you are using the right cord.

Install GFCI Protection

If there are unsafe conditions at the workplace, installing GFCI Protection can help prevent electric shocks and save lives. GFCI means Ground Fault Circuit Interrupter, a device that intercepts electric flow, avoiding electric shocks from faults in electrical appliances.

The device measures the current flowing from a plug and disconnects it when it detects a power spill. So, it does more than save you cord inspection time, as it responds promptly (in less than 1/40 of a second) to potentially hazardous incidents to prevent injuries.

However, GFCI has its limitations and won’t protect you if you touch live wires. Its main purpose is to protect you against shocks, overheating, fires, and damaged wire insulation. But it's important to use GFCI on all electrical cords at workplaces to keep workers safe. Besides, the device is not costly.

Proper Storage

Whether moving to a new workplace or simply storing extension cords for future use, you must use the right techniques to store extension cords properly. Depending on the type of the cord, there are several ways to do this to ensure they maintain their good condition. Knowing the right way to warp your extension cords keeps them from tangling and makes storage easy.

Be Mindful of Weather Conditions

Be mindful of bad weather conditions that could damage the extension cords when working outside. Generally, extension cords rated for outdoor usage should withstand harsh weather conditions outdoors. However, you should avoid keeping the cord plugged into the socket while it is raining as it can damage the cord and become a hazard.

Ensure that you are constantly aware of the condition of your building and regularly carry out an electrical equipment inspection. Doing this ensures that the building or business is safe from potential hazards.

Check for Damage

It is essential to inspect the extension cord regularly to avoid using damaged cords as they pose a significant danger to the users. The best solution is to dispose of and replace them.

Before using an extension cord, ensure it's not damaged. And if you notice any damage, don't try fixing it by yourself, like by patching them up with electrical tape. Let a qualified person fix it and ensure everything is done correctly, evading future accidents.

Don’t Substitute Cords for Fixed Wiring.

Some people may be tempted to use extension cords as a substitute for fixed wiring by running cords through holes in the walls, ceilings, or floors. However, this is a bad idea since when covered, heat cannot escape, which may cause fire hazards. Therefore, you cannot conceal extension cords behind walls, ceilings, and floors. Besides, attaching extension cords to walls or ceilings using metal nuts can damage its outer cover. The covers are usually soft enough to be flexible, making them vulnerable to damage. Mishandling during installation can also stimulate wear and tear.

One more thing, extension cords don't offer permanent solutions to your power supply. So, you should never substitute it with permanent writing. If you need extra power for long-term use, consider using an electrician to mount convenient outlets in your facility.

The Dos and Don'ts When Using Industrial Extension Cords:

• Unplug the extension cord from the outlet when not in use.
• Check for the UL Mark in your extension cord to verify that it's been tested for all possible safety hazards.
• Inspect the extension cord for cracks before using them and replace damaged ones immediately.
• Do not touch an exposed wire to avoid electric shock.
• Keep the cords in good conditions indoors when not in use to prevent damage.
• Use water-resistant extension cords designed for outdoor use when working outdoors.
• Ensure the outdoor cord is free from standing water and is in a well-protected place.
• Never run indoor extension cords under equipment or carpeting to prevent overheating.
• Avoid running the cords through holes in walls, windows, or doorways.
• If the plug or extension cord needs fixing, use a qualified electrician.
• Never touch extension cords or plug them in the power outlet with wet hands.
• Remember, extension cords should offer a permanent solution to your power needs.

Conclusion

Extension cords are essential accessories in factories and even on business premises. Cords will come in handy when you want to operate heavy machines outside, hang lights or simply supply appliances with power if there is no plug nearby. However, they come in various designs to suit different functions. You need to pick the right extension cord for your power demand and other workplace needs. To guarantee the safety of workers, these are crucial tips to keep in mind when using extension cords.

It all comes down to exercising caution and using the right cords and equipment in your operations. Following these guidelines ensures that your extension cords cause no harm at the workplace, protecting workers from injuries and accidents.