1910.254(d)(9)(iii): Replacing Damaged Welding Cables
Employers must replace welding cables that have damaged insulation or exposed bare conductors. Work and electrode cable lengths may be joined only with connecting means made for that purpose, with insulation adequate for the service conditions.
Key takeaways
- 1910.254(d)(9)(iii) is part of OSHA's general industry standards (29 CFR Part 1910, Subpart Q).
- OSHA cited it 79 times in the last 3 years, in 79 inspections, with $237,473 in current penalties.
- Most citations: NY (10), TN (7), VA (6).
- Related part: 1910.254(d) Operation and maintenance (95 citations).
- Free 5-minute toolbox talk for your crew below.
In this article
What this rule covers
29 CFR 1910.254(d)(9)(iii) is one requirement inside 1910.254 Arc welding and cutting, an OSHA general industry standard (Part 1910, Subpart Q). The official text below is copied word for word from the Electronic Code of Federal Regulations (eCFR). The numbers, injury cases and training on this page show how OSHA enforces it on real job sites.
Official text
(iii) Cables with damaged insulation or exposed bare conductors shall be replaced. Joining lengths of work and electrode cables shall be done by the use of connecting means specifically intended for the purpose. The connecting means shall have insulation adequate for the service conditions. 79 citations
[55 FR 13696, Apr. 11, 1990, as amended at 61 FR 9241, Mar. 7, 1996; 70 FR 53929, Sept. 13, 2005]
Source: eCFR, text current as of 2026-10-15. Read all of 1910.254.
Where and how often it was cited
| Year | Citations |
|---|---|
| 2023 | 4 |
| 2024 | 35 |
| 2025 | 28 |
| 2026 | 12 |
Top states: NY (10), TN (7), VA (6), MN (6), TX (5)
Largest penalties
| Employer | Location | Penalty for this rule |
|---|---|---|
| VTCU, CORP. | POCATELLO, ID | $70,938 |
| ZACHRY MAINTENANCE SERVICES, LLC | MANSFIELD, LA | $16,131 |
| LIEBHERR AMERICA | NEWPORT NEWS, VA | $13,840 |
| POLARIS, INC. | MADISON, AL | $12,905 |
| CARL'S DONUTS, INC. | LAS VEGAS, NV | $8,036 |
Free toolbox talk
A 5-minute crew talk on 1910.254(d)(9)(iii), plus alerts when this rule changes. Free.
OSHA interpretation letters
- OSHA's General Industry standard requires damaged welding leads to be replaced and not to be repaired. (2005-04-05)
Related parts of this rule
- 1910.254(d) Operation and maintenance 95 citations
- 1910.254(d)(9) Maintenance 83 citations
Get your crew competent
Trainers on Black Belt Safety: Marc Harvey, Dana Reyes
Trainers and suppliers: feature your business on this rule for $25/month.
Frequently asked questions
What must happen to a welding cable with damaged insulation?
It must be replaced.
Can I splice welding cables with tape?
Lengths must be joined only with connecting means specifically intended for the purpose.
How well insulated must the connectors be?
The connecting means must have insulation adequate for the service conditions.
About this page
Sources
- 29 CFR 1910.254 (eCFR), text current as of 2026-10-15
- U.S. Department of Labor enforcement data: OSHA inspections, citations and accident records, copied nightly; data as of 2026-10-22
3-year window. Federal OSHA only; state-plan rules are not counted. Plain-language text is a summary, not legal advice; the official text controls. Black Belt Safety is not part of OSHA or the Department of Labor.