Power Cord Safety

Extension Cord Safety

Power cords are often overlooked, but they’re a critical part of power tool safety. Using the wrong cord or using a cord the wrong way can lead to overheating, tool damage, or even fire. Here’s what you need to know to stay safe and keep your tools running right.

Power Cord Ratings

Gauge (AWG): The lower the number, the thicker the wire. Thicker cords carry more current with less resistance.

  • 14-gauge: Good for light-duty tools under 50 feet
  • 12-gauge: Better for most power tools, especially beyond 50 feet
  • 10-gauge: Heavy-duty tools, long distances

Amps: Match the cord to your tool’s amperage rating. Never use a cord that can’t handle your tool’s draw.

Voltage Drop: The longer the cord, the more voltage drop you get—especially with smaller gauges. This can cause tools to underperform or overheat.

Cord Length and Performance

  • Under 25 feet: Most gauges are fine for light to medium-duty tools
  • 25–50 feet: Use 12-gauge minimum for most tools
  • Over 50 feet: Use 10-gauge for anything drawing serious power
  • Avoid daisy chaining: Connecting multiple cords increases resistance and risk

Power Cord Safety Tips

  1. 1
    Inspect Before Use: Look for cuts, frays, or exposed wires. Damaged cords should be replaced immediately.
  2. 2
    Avoid Coiling While in Use: Heat builds up inside tightly coiled cords, increasing fire risk.
  3. 3
    Use Outdoor-Rated Cords Outside: Indoor cords lack the insulation to handle moisture and temperature changes.
  4. 4
    Don’t Overload Circuits: Know your breaker’s limits. Running multiple high-amp tools on one outlet can trip breakers or overheat cords.
  5. 5
    Pull from the Plug, Not the Cord: This prevents damage to the internal wiring and connection points.

Proper Storage and Handling

  • Loosely Coil Cords: Use wide loops, tight wrapping damages the internal copper strands.
  • Hang on Wall Hooks: Keeps cords off the floor and reduces tripping hazards.
  • Label Your Cords: Add tags for gauge and length so you can quickly grab the right one for the job.
  • Keep Dry: Store cords in a dry area, preferably off the ground, to avoid corrosion and wear.

Extension Cord Don’ts

  • Don’t run cords under rugs or through doorways
  • Don’t plug a high-amp tool into a cheap household extension cord
  • Don’t use damaged cords with electrical tape as a long-term fix
  • Don’t use indoors-rated cords outside—even “just for a minute”

Final Thoughts

A power cord might seem like a simple accessory, but it plays a big role in tool performance and workshop safety. Use the right cord for the job, inspect it regularly, and store it correctly to protect yourself and your tools.