We will be discussing the electrical accidents in the workplace. Our workplaces are flooded with so many hazards that could result in accidents; one of the accidents is the electrical accident. At the end of this article, you will understand what electrical accidents are, examples of electrical accidents, and how they could be prevented.
Let’s consider what electrical accidents are.
What Are Electrical Accidents
An electrical accident is said to be an unplanned, unwanted, and undesired event that could result in injury to a person or damage to property.
The only significant difference between an electrical accident and other forms of accidents is that in an electrical accident, the culprit is the electric current.
Electrical accidents are far more common than you might think. According to the UK’s Electrical Safety First, around 19,300 domestic fires with an electrical cause occur in the UK every year. These fires can be caused by anything from faulty leads to misuse of appliances. So, it’s important to know what causes electrical accidents and what you can do to prevent them.
Causes of Electrical Accidents
According to the UK’s Health and Safety Executive (HSE), there are 12 common causes of electrical accidents that happen while equipment is being maintained:
- Unsafe system of work
- Inadequate information
- No training
- Inadequate isolation
- Unsafe rules
- Poor control of work activities
- Live working
- Unsuitable test equipment
- Poor maintenance
- Failure to manage work
- Person not competent
- Uninsulated electrical wiring
Electrical Accidents In The Workplace
1. Electric Shock Due to Faulty Equipment
Scenario:
James, an office maintenance technician, was asked to replace a faulty water dispenser. In a rush to complete his tasks before lunch, he failed to inspect the electrical cord thoroughly. As soon as he plugged it into the socket, he felt a jolt travel up his right arm and fell back screaming. The dispenser had an exposed wire under its plug, which contacted his sweaty hand during the operation.
Explanation:
An electric shock occurs when the body becomes part of an electrical circuit, allowing current to pass through. Faulty equipment—such as frayed wires, exposed conductors, and defective insulation—is are common culprit. Shocks can range from mild tingling to fatal cardiac arrest, depending on voltage, current path, and duration of contact. In James’ case, moisture and improper handling heightened the risk.
In workplaces, particularly maintenance departments, worn-out tools and appliances are often overlooked until something catastrophic occurs. To prevent electric shock, all electrical tools should be regularly inspected, tagged, and tested. Employees should be trained in identifying signs of wear or malfunction and encouraged to report or isolate unsafe tools. Personal protective equipment (PPE), such as rubber gloves and insulated boots, adds another layer of defense.
The key takeaway is to never assume any electrical equipment is safe unless proven otherwise. Lock-out/tag-out (LOTO) procedures and a preventive maintenance schedule are essential in mitigating these risks.
2. Arc Flash Explosion
Scenario:
During a routine switchgear inspection in a manufacturing plant, Carlos opened the electrical panel without proper PPE. As he reached to check a breaker, a high-energy arc flash erupted, creating a fireball that scorched his face, burned his arms, and caused temporary blindness. Fortunately, he survived, but he required months of treatment and rehabilitation.
Explanation:
An arc flash is a sudden release of electrical energy through the air when a high-voltage gap exists and breakdown occurs. It can reach temperatures up to 35,000°F (hotter than the sun’s surface), capable of vaporizing metal, causing fatal burns, and igniting clothing instantly. These incidents are often triggered by accidental contact, faulty breakers, or dropped tools.
Carlos’s accident is a textbook example of poor risk assessment and violation of safety protocols. He failed to wear arc-rated PPE, didn’t de-energize the panel, and lacked arc flash boundary awareness. In many industries, workers underestimate the invisible danger posed by energized electrical components.
To prevent arc flashes, employers should enforce strict adherence to NFPA 70E standards. A proper arc flash study should be conducted, and panels must display hazard labels indicating arc flash boundaries and PPE requirements. Lock-out/tag-out procedures, insulated tools, and safe working distances should be emphasized in safety training.
Arc flash training is not optional—it’s a life-saving requirement. Employees must know the consequences of complacency in high-voltage environments.
3. Overloaded Circuits Causing Fire
Scenario:
In a busy retail store, employees connected multiple devices—computers, printers, scanners, and heaters—into one power strip. Over time, the load exceeded the rated capacity of the strip and the wall socket. One morning, a faint burning smell led to the discovery of melted insulation and a small fire behind the cash register area.
Explanation:
Overloading circuits is a widespread but often ignored hazard. When too many devices are plugged into a single outlet, the circuit can exceed its maximum load, causing overheating, arcing, and eventually fire. Extension cords and power strips are meant for temporary use and have limits that must be respected.
In this scenario, the store’s reliance on a single outlet for numerous devices created a fire hazard. Electrical fires are particularly dangerous because they often start hidden behind walls or furniture, giving little warning before they escalate.
To prevent overload, circuit breakers and fuses must be correctly rated, and employees should be educated on safe load practices. A certified electrician should assess high-demand areas and install dedicated circuits or outlets. Power strips should be surge-protected and ideally equipped with overload protection.
Routine inspections, load calculations, and awareness campaigns can go a long way in mitigating fire risks from overloaded circuits.
4. Contact with Overhead Power Lines
Scenario:
On a construction site, a crane operator was lifting steel beams when the crane boom accidentally touched an overhead high-voltage power line. The operator and a ground worker suffered severe electrical burns. Emergency responders later revealed the crane had not maintained the minimum clearance distance required by local regulations.
Explanation:
Overhead power lines carry extremely high voltages and are one of the leading causes of fatal electrical injuries in construction. Workers operating tall equipment like cranes, ladders, or scaffolding are at particular risk.
In this case, the crane made direct contact, allowing electricity to travel through the metal structure to the operator and ground personnel. Electricity always seeks the shortest path to ground, and in many outdoor scenarios, workers inadvertently complete that path.
Prevention starts with proper site planning. Employers must identify and mark all overhead power lines and enforce minimum clearance distances (typically 10 feet for up to 50kV, more for higher voltages). Equipment operators must be trained in power line awareness and use spotters when working near live lines.
De-energizing lines or using insulating barriers is the safest option, but when that’s not possible, extreme caution must be applied. Lives depend on respecting invisible boundaries.
5. Improper Use of Extension Cords
Scenario:
At a warehouse, employees routinely used a long extension cord to power a portable fan. Over time, the cord’s insulation wore out due to foot traffic and being pinched under pallets. One day, an employee walked over the cord with wet boots and received a serious electric shock that knocked him unconscious.
Explanation:
Extension cords are among the most abused electrical tools. Designed for temporary use, they’re often treated as permanent wiring solutions, exposed to physical damage, moisture, or overloading. Damaged cords can expose live wires, turning them into serious electrocution hazards.
In this warehouse, the extension cord had become a permanent fixture, and its placement in a high-traffic area increased the risk of wear and tear. The wet conditions made matters worse, providing a conductive path for electricity.
Workplaces should eliminate the routine use of extension cords. If equipment needs to be relocated or used regularly, permanent outlets should be installed. All cords in use must be heavy-duty, grounded, rated for the equipment’s load, and visually inspected before use.
Cord management—such as using cord covers, routing overhead, and keeping cords dry—is essential. Employees should be trained to recognize when extension cords are being misused and to report frayed or damaged cords immediately.
6. Wet Conditions and Electrical Equipment
Scenario:
Maria, a cleaner in a commercial kitchen, used a floor scrubber early in the morning while mopping around a refrigerator unit. Unknown to her, the plug had a minor crack, and as water seeped into the outlet, she experienced a jolt that threw her backward. Fortunately, she survived but sustained a shoulder injury.
Explanation:
Electricity and water are a dangerous mix. Wet environments increase the conductivity of the human body, making it easier for current to travel through. Kitchens, wash bays, and outdoor worksites are particularly prone to this type of accident.
In Maria’s case, the cracked plug allowed water to reach internal components, creating a live circuit. The combination of conductive surfaces, bare skin, and moisture made her especially vulnerable.
To prevent such incidents, Ground Fault Circuit Interrupters (GFCIs) should be installed in all wet or damp locations. GFCIs detect leakage currents and cut power instantly to prevent shock. Equipment used in wet areas should be rated for moisture resistance (IP rated) and routinely checked for signs of wear or cracking.
Employees should be trained to never operate electrical equipment with wet hands or on wet surfaces. Proper footwear (non-conductive, slip-resistant) and dry hands are essential. Regular inspections and strict protocols for cleaning near electrical equipment must be enforced.
7. Inadequate Lockout/Tagout Procedures
Scenario:
A maintenance technician entered the factory floor to repair a conveyor belt motor. Although the motor was believed to be switched off, it was not locked out. While the technician’s hands were inside the motor assembly, another worker unknowingly restarted the system, causing severe crushing injuries.
Explanation:
Lockout/Tagout (LOTO) is a vital safety procedure that ensures energy sources are completely de-energized and remain so while maintenance or servicing is underway. Inadequate LOTO is one of the most cited violations by OSHA and often results in serious injuries or fatalities.
The technician’s accident illustrates the consequences of assuming a machine is safe without physical isolation. Lockout involves placing a lock on the power source, while tagout involves placing a warning label. Without these in place, any authorized employee can unintentionally reactivate the system.
Proper LOTO programs involve identifying energy sources, training employees, issuing personal locks, and auditing procedures regularly. Every maintenance job must follow a step-by-step protocol to verify zero energy and test before touching.
Supervisors play a key role in enforcing LOTO discipline. One lapse can result in a lifetime of regret.
8. Exposed Live Wires
Scenario:
During office renovation, an electrician left a partially installed power outlet with exposed wires covered only with tape. A curious employee leaned down to plug in a charger and accidentally touched the wire, suffering burns on her fingers.
Explanation:
Exposed live wires are a serious hazard, often resulting from unfinished work, poor insulation, or damaged fixtures. Even low-voltage systems can deliver a dangerous shock or cause a fire if left unprotected.
The electrician in this case failed to terminate or isolate the wiring properly. Makeshift solutions like taping over live wires are never acceptable. Any wire not in use should be capped, locked out, or placed inside a certified enclosure.
Employers should implement a strict policy that prohibits unauthorized access to electrical installations. Warning signs, physical barriers, and regular inspections should be used in any workspace undergoing electrical work.
Electrical installations should only be carried out by licensed professionals who understand the code requirements. No shortcuts should be allowed—especially when lives are at stake.
9. Use of Non-Qualified Personnel for Electrical Work
Scenario:
The IT department in a startup decided to run additional network cables. Instead of calling an electrician, the team tried to tap into an existing power socket. During the process, one staff member accidentally crossed wires, causing a power surge that fried multiple computers and resulted in minor electric burns.
Explanation:
Using non-qualified personnel to perform electrical work is both illegal and dangerous. Electrical systems are complex, and errors in wiring, grounding, or connections can result in electrocution, equipment damage, or fires.
In the startup’s case, the employees had good intentions but lacked proper training and licensing. Their mistake led to financial loss and placed lives at risk. This situation is common in small businesses where there’s pressure to cut costs or “do it ourselves.”
Employers must ensure that all electrical work is performed by certified electricians. Risk assessments should be conducted before any task involving electricity. Employees should be trained to recognize the boundaries of their responsibilities and know when to call in professionals.
Regulations and Standards Relating to Electricity
Many regulations and standards address working safely around electricity. The information in this course is based on key OSHA regulations and the National Fire Protection Association’s (NFPA) 70E, Standard for Electrical Safety in the Workplace.
Below are some of the most important regulations and what they address:
- OSHA 29 CFR 1910, Subpart I: Personal Protective Equipment. Section 1910.137
Specifically addresses electrical protective devices. - OSHA 29 CFR 1910, Subpart P: Safe operation of hand and portable powered tools and
other hand-held equipment. - OSHA 29 CFR 1910, Subpart S: Electrical safety requirements necessary for the practical
Safeguarding of employees in the workplace. - OSHA 29 CFR 1910.147: Lockout/tagout procedures. Describes how to service or
Maintain equipment that might unexpectedly energize. - OSHA 29 CFR 1910.333: Lockout/tagout procedures. Describes how to service or
maintain energized circuits.
To prevent these accidents, workplaces should implement strict safety protocols like LOTO, provide proper training, regularly inspect and maintain electrical equipment, and ensure compliance with relevant safety standards and regulations. Additionally, personal protective equipment (PPE) should be used, and employees should be encouraged to report and address any potential electrical hazards promptly.
How to Avoid Electrical Accidents at Work
There are a number of measures employers (and employees) can take to minimise the risk of electrical accidents at work.
The Health and Safety Executive recommends a series of simple precautions, which include:
- Performing a risk assessment for the work you are planning and any potential electrical hazards involved
- Identifying where it is safe to work and putting up danger signs to highlight unsafe areas
- Making sure that employees are adequately trained to use electrical equipment and machinery
- Ensuring that electrical equipment is properly maintained and regularly checked before use