Workshop Electrical Safety: Extension Leads, RCDs, and Power Boards

Every Australian workshop, whether a professional trade space or a home garage, runs on electricity. Power tools, lighting, ventilation, and countless other equipment depend on a safe and reliable electrical supply. Yet electrical hazards remain a significant cause of workshop injuries and fatalities, along with being a leading cause of workshop fires.

This comprehensive guide covers essential electrical safety knowledge for Australian workshop environments. From understanding RCD protection to safely using extension leads and power boards, you'll learn how to create and maintain a workshop electrical system that protects you, your family, and your property.

Understanding Electrical Hazards

Before discussing protection measures, it's important to understand what we're protecting against. Electrical hazards in workshops include:

Electric Shock

When electrical current passes through the human body, the results range from minor tingling to cardiac arrest and death. The severity depends on current magnitude, pathway through the body, and duration. Wet conditions, common in workshops from rain, spills, or perspiration, dramatically increase shock risk by reducing skin resistance.

Electrical Burns

High current flow can cause severe burns, both externally and internally. Arc flash incidents, where electrical current travels through air, can cause explosive burns and blindness.

Electrical Fires

Overloaded circuits, damaged cables, and poor connections generate heat that can ignite surrounding materials. Workshop environments often contain flammable materials like sawdust, solvents, and oily rags that increase fire risk.

RCDs: Your Essential Protection

Residual Current Devices (RCDs), also called safety switches, are the most important electrical safety device in any workshop. Understanding how they work and ensuring adequate protection is crucial.

How RCDs Work

RCDs continuously monitor the current flowing out through the active wire and returning through the neutral wire. These values should be equal. If current "leaks" to earth—perhaps through a person receiving a shock—the imbalance triggers the RCD to cut power within milliseconds, potentially saving a life.

RCD Types and Ratings

Standard personal protection RCDs trip at 30mA (0.03 amps) imbalance, fast enough to prevent electrocution in most circumstances. Fire protection RCDs rated at 300mA protect against fire risk from larger fault currents but may not prevent electrocution.

Workshop RCD Requirements

Australian regulations require RCD protection for power circuits in new installations, but older workshops may lack adequate protection. For workshop safety:

• All power circuits should be protected by 30mA RCDs
• Consider separate RCDs for different circuits to prevent total workshop shutdown when one trips
• Install combination RCD/circuit breakers (RCBOs) for best protection
• Test RCDs monthly using the built-in test button

Extension Leads: Use Them Safely

Extension leads are workshop essentials, but they're frequently misused in ways that create serious hazards.

Choosing the Right Lead

Extension leads are rated for specific current capacities. Using an undersized lead with high-draw tools causes overheating that can melt insulation and cause fires. Check ratings carefully:

• Light duty (10A): Suitable for low-power devices, lights, and charging
• Medium duty (10A heavy): Standard power tools like drills and sanders
• Heavy duty (15A): High-draw tools like circular saws, routers, and welders

When in doubt, use a heavier-rated lead than you think necessary.

Extension Lead Best Practices

• Fully unroll leads before use—coiled leads can overheat even at moderate loads
• Never run leads through doorways where they can be damaged by closing doors
• Keep leads away from water, oil, and sharp edges
• Never daisy-chain multiple extension leads
• Inspect leads regularly for damage to plugs, cables, and sockets
• Replace damaged leads immediately—never tape over damaged insulation
• Don't run leads under rugs or mats where heat can build up

Outdoor and Wet Conditions

When using extension leads outdoors or in damp workshop conditions:

• Use leads rated for outdoor use (marked on the cable)
• Keep connections off the ground and protected from water
• Always use RCD protection
• Inspect connections before use when they've been exposed to weather

Power Boards: Managing Multiple Connections

Power boards (power strips) are convenient but frequently overloaded. Safe use requires understanding their limitations.

Load Limits

Standard power boards are typically rated for 10A total load across all outlets. This is easily exceeded when running multiple power tools or high-draw equipment. Calculate your total load and never exceed the power board's rating.

Power Board Safety Rules

• Never connect one power board to another (daisy-chaining)
• Don't use power boards for high-continuous-load appliances like heaters or air conditioners
• Use power boards with built-in overload protection
• Position power boards where they won't be damaged or create trip hazards
• Consider surge-protected power boards for sensitive equipment

Maintaining Workshop Electrical Safety

Regular Inspections

Develop a habit of inspecting electrical equipment before each use:

• Check power cables for damage, cuts, or exposed wires
• Examine plugs for cracks, burn marks, or loose connections
• Look for signs of overheating on outlets and power boards
• Test RCDs monthly using their test buttons
• Verify ground connections on double-insulated tools are intact

Responding to Electrical Problems

If you experience electrical issues:

• Tingling or shock: Stop immediately. Have the tool and circuit inspected by an electrician.
• Tripping RCDs: Don't keep resetting—investigate the cause. Could indicate faulty equipment or wiring.
• Burning smells or smoke: Disconnect immediately. Don't use until inspected.
• Flickering or dimming lights: May indicate loose connections or overloaded circuits.

Professional Electrical Work

In Australia, electrical work must be performed by licensed electricians. This includes:

• Installing or modifying fixed wiring
• Adding or relocating power outlets
• Switchboard modifications or upgrades
• Installing RCDs or circuit breakers
• Connecting fixed equipment like welders or dust extraction systems

DIY electrical work is illegal and dangerous. The savings aren't worth the risk to life and property, and insurance may be voided by unlicensed work.

Emergency Preparedness

Prepare for electrical emergencies before they occur:

• Know the location of your main switchboard and how to turn off power
• Keep a torch near the switchboard for use during power outages
• Have a fire extinguisher rated for electrical fires (CO2 or dry powder) accessible
• Know how to safely rescue someone experiencing electric shock (turn off power first if possible, or use non-conductive material to separate them from the source)
• Keep emergency numbers posted visibly

Summary: Workshop Electrical Safety Checklist

• Ensure all circuits have 30mA RCD protection
• Test RCDs monthly
• Use appropriately rated extension leads and power boards
• Inspect equipment before each use
• Never use damaged cables, plugs, or equipment
• Don't overload circuits or power boards
• Keep electrical connections away from water and moisture
• Use licensed electricians for all fixed electrical work
• Be prepared for electrical emergencies

Electrical safety isn't glamorous, but it's fundamental to a productive workshop where you can work confidently for years to come. Take the time to assess your workshop's electrical systems and address any shortcomings—your safety depends on it.