Electrical equipment is used in almost every workplace. From power tools and extension leads to office equipment, kitchen appliances and battery chargers, it is easy to assume that if something still works, it is safe to use. 

Unfortunately, that assumption has contributed to many workplace electric shocks, fires and serious injuries. 

One of the simplest ways to reduce electrical risk is to recognise when electrical equipment has become unsafe and remove it from service immediately. 

If You Think It’s Unsafe, Stop Using It 

A common mistake is continuing to use damaged equipment because: 

• “It still works.”
• “We’ll replace it next week.”
• “It’s only a small crack.”
• “We’ll just be careful.”

The law doesn’t require electrical equipment to completely fail before action is taken. If equipment is damaged and presents a risk, it should be removed from service until it has been repaired by a competent person or replaced. 

What Damage Should You Look For? 

Workers should inspect electrical equipment before use and report any damage immediately. 

Common signs include: 

• Cuts, splits or exposed wires on power cords.
• Damaged plugs or bent pins.
• Cracked, broken or melted casings.
• Loose switches or power sockets.
• Burn marks or signs of overheating.
• Electrical tape wrapped around damaged cords.
• Missing covers or guards.
• Equipment that has been dropped or crushed.
• Water damage or evidence of moisture entering the equipment.
• Unusual noises, sparks, smoke or burning smells.

If any of these are found, the equipment should not be used. 

Don’t Try Temporary Repairs 

One of the most common hazards seen during workplace inspections is damaged electrical leads wrapped in electrical tape. 

Electrical tape is not an acceptable repair. 

Similarly: 

• Do not twist wires together.
• Do not glue broken electrical casings.
• Do not bypass safety features.
• Do not continue using equipment that intermittently loses power.

Temporary fixes often hide the problem rather than eliminate the risk. 

What Should Workers Do? 

Every worker should know the simple process: 

• Stop using the equipment immediately.
• Disconnect it safely if possible.
• Attach an “Out of Service” or “Do Not Use” tag.
• Report the defect to their supervisor.
• Arrange for inspection, repair or replacement by a competent person.

Removing unsafe equipment quickly is one of the easiest ways to prevent electrical incidents. 

The Importance of Reporting Damage 

Many electrical incidents occur because workers notice damage but assume someone else has already reported it. 

Creating a workplace culture that encourages employees to report defects immediately is just as important as conducting formal inspections. 

A damaged extension lead left lying in a workshop or warehouse can become the next person’s serious injury. 

Regular Inspections Matter 

Formal inspections should be carried out as part of your workplace electrical safety program. 

These inspections should include: 

• Portable electrical equipment.
• Extension leads.
• Power boards.
• Battery chargers.
• Portable Residual Current Devices (RCDs).
• Office equipment.
• Workshop tools.

Higher-risk workplaces such as construction sites, manufacturing facilities, warehouses and workshops may require more frequent inspection and testing than low-risk office environments. 

Remember: Testing Doesn’t Replace Visual Inspections 

Testing and tagging are only one control measure. 

Many electrical hazards can be identified during a simple visual inspection before equipment is plugged in. 

Workers should never assume equipment is safe simply because it has a current test tag. 

Damage can occur at any time after testing. 

Employer Responsibilities 

Under Australian work health and safety laws, persons conducting a business or undertaking (PCBUs) must ensure electrical equipment is safe to use, inspected and maintained, and that damaged equipment is not used if it poses a risk. 

This includes providing systems for workers to report defects and ensuring that unsafe equipment is promptly removed from service. 

Practical Tips for Every Workplace 

A few simple habits can significantly reduce electrical risks: 

• Encourage workers to complete a quick visual inspection before use.
• Remove damaged equipment from service immediately.
• Provide “Out of Service” tags in work areas.
• Never allow makeshift repairs.
• Keep a register of defective equipment until repaired or disposed of.
• Train workers on how to identify electrical hazards.
• Include electrical equipment inspections in routine workplace inspections.

Final Thoughts 

Electrical equipment rarely fails without warning. Small signs of damage are often the first indication that something is wrong. 

By encouraging workers to inspect equipment before use, report defects immediately and remove damaged items from service, businesses can prevent many electrical incidents before they occur. 

Electrical safety isn’t just about complying with legislation – it’s about making sure every worker goes home safely at the end of the day.

Key References 

• Model Code of Practice: Managing Electrical Risks in the Workplace (Safe Work Australia)

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