On-site repair of localised cord and plug damage — restoring equipment to safe working condition without full replacement.
Cord Repairs
Overview
Digital Compliance Reporting & Records
Cord repair is the on-site restoration of portable electrical equipment when testing reveals localised damage to power cords, plugs, connectors, or inline switches. Repair is appropriate when the dama...
- Localised cord and plug damage is the most common reason for portable appliance test failures — and in many cases, the equipment itself is perfectly functional and does not need to be replaced.
- Professional repair uses correctly rated, AS/NZS approved components — ensuring the repaired item is genuinely safe, not just superficially fixed.
- On-site repair means equipment can be returned to service the same day, avoiding the cost and delay of sending items away or purchasing replacements.
- Repairing is often significantly more cost-effective than replacing entire appliances, especially for higher-value equipment like power tools, kitchen appliances, and IT equipment.
Damaged Cord
Frayed or exposed wiring
Inspection
Assess damage extent
On-Site Repair
Cord/plug replaced
Retested & Passed
Safe to return to service
Why It Matters
Why Cord Repairs matters
Localised cord and plug damage is the most common reason for portable appliance test failures — and in many cases, the equipment itself is perfectly functional and does not need to be replaced.
Professional repair uses correctly rated, AS/NZS approved components — ensuring the repaired item is genuinely safe, not just superficially fixed.
On-site repair means equipment can be returned to service the same day, avoiding the cost and delay of sending items away or purchasing replacements.
Repairing is often significantly more cost-effective than replacing entire appliances, especially for higher-value equipment like power tools, kitchen appliances, and IT equipment.
Common Issues
Common Cord Repairs faults
Frayed cord near plug entry point
The most common cord fault — repeated bending at the plug entry point causes conductor strands to break and insulation to crack, exposing live conductors.
Damaged section cut back and cord re-terminated into a new approved plug with proper strain relief.
Cracked or broken plug housing
Live pins become accessible, creating a high risk of electric shock for anyone handling the appliance.
Plug replaced with an approved heavy-duty replacement rated for the equipment's current draw.
Worn or loose connector
Loose connections cause arcing and overheating, which can melt housings and start fires.
Connector replaced or repaired with correctly rated component and item retested.
Faulty inline switch
Faulty switches can fail to isolate power, create shock hazards, or overheat under load.
Inline switch replaced with approved replacement and item retested.
Testing Frequency
How often should you test?
Inspection & Testing Intervals
Recommended inspection and testing frequencies based on AS/NZS 3760 for different workplace environments and equipment types.
Caution
This information should be read together with the AS/NZS 3760 standard as a whole, particularly Clause 2.1. Inspection intervals vary depending on equipment type and operating environment.
| Type of environment and/or equipment (a) | Equipment including Class I equipment, Class II equipment, cord sets, cord extension sets and EPOD’s (b) | Interval between inspection and tests | |||
|---|---|---|---|---|---|
| Residual Current Devices (RCD’s) | |||||
| Push Button test by user | Operating time and push-button test | ||||
| Portable (c) | Fixed (d) | Portable (e) | Fixed (f) | ||
1. Factories, workshops, places of work or repair manufacturing, assembly, maintenance or fabrication | 6 months | Daily, or before every use, whichever is the longer | 6 months | 12 months | 12 months |
2. Environment where the equipment or supply flexible cord is subject to flexing in normal use OR is open to abuse OR is in a hostile environment | 12 months | 3 months | 6 months | 12 months | 12 months |
3. Environment where the equipment or supply cord is NOT subject to flexing in normal use and is NOT open to abuse and is NOT in a hostile environment | 5 years | 3 months | 6 months | 2 years | 2 years |
4. Residential type areas of hotels, residential institutions, motels, boarding houses, halls, hostels, accommodation houses, and the like | 2 years | 6 months | 6 months | 2 years | 2 years |
5. Equipment used for commercial cleaning | 6 months | Daily, or before every use, whichever is the longer | NA | 6 months | NA |
6. Hire Equipment Inspection | Prior to hire | Including push-button test by hirer prior to hire | NA | NA | NA |
Test and Tag | 3 months | NA | NA | 3 months | 12 months |
7. Repaired, serviced and second-hand equipment | After repair or service which could affect electrical safety, or on reintroduction to service, refer to AS/NZS 5762 | ||||
1Factories, workshops, places of work or repair manufacturing, assembly, maintenance or fabrication
2Environment where the equipment or supply flexible cord is subject to flexing in normal use OR is open to abuse OR is in a hostile environment
3Environment where the equipment or supply cord is NOT subject to flexing in normal use and is NOT open to abuse and is NOT in a hostile environment
4Residential type areas of hotels, residential institutions, motels, boarding houses, halls, hostels, accommodation houses, and the like
5Equipment used for commercial cleaning
6Hire Equipment
Inspection
Test and Tag
7Repaired, serviced and second-hand equipment
After repair or service which could affect electrical safety, or on reintroduction to service, refer to AS/NZS 5762
Important Note
Inspection frequencies depend on equipment type, condition, and working environment. Hostile environments require more frequent inspection and testing. Always refer to AS/NZS 3760 or contact our team if you are unsure which interval applies to your workplace.
Our Process
How Cord Repairs works
Our streamlined process ensures every cord repairs engagement is efficient, thorough, and fully documented.
Damage Identification
During the testing and inspection process, the technician identifies cord or plug damage and assesses whether repair is appropriate.
Repairability Assessment
The technician determines whether the damage is localised and repairable, or whether the item requires full cord replacement or removal from service.
Repair Quote
A clear, itemised repair quote is provided before any work commences — so you know exactly what the repair will cost and can approve it on the spot.
On-Site Repair
The technician completes the repair using quality, AS/NZS approved parts with proper strain relief and termination.
Retesting & Documentation
The repaired item is immediately retested. Repair details and retest results are recorded in your compliance report.
What's Tested
Cord Repairs checklist
Damage Assessment
The technician inspects the damaged cord, plug, connector, or inline switch to determine whether repair is a safe and appropriate option.
Cord Re-Termination
Where cord damage is localised near the plug, the damaged section is cut back and the cord re-terminated into a new approved plug.
Plug Replacement
Cracked, damaged, or worn plugs replaced with new approved heavy-duty plugs rated for the equipment's current draw.
Connector & Switch Repair
Faulty connectors, inline switches, and couplings repaired or replaced with correctly rated components.
Retesting
All repaired items are immediately retested using calibrated equipment to confirm they meet AS/NZS 3760 requirements before return to service.
What You Receive
What you receive
Repaired Equipment
Equipment restored to safe working condition and returned to service the same day — minimising downtime and avoiding replacement costs.
Retest Confirmation
Written confirmation that the repaired item passes all required AS/NZS 3760 safety tests and is safe to return to service.
Compliance Record
Repair details and retest results documented in your digital compliance system, providing a complete audit trail.
Benefits
Why choose our cord repairs service
On-Site Repairs
Common repairs completed on-site during the testing visit. No need to send equipment away.
Immediate Restoration
Failed equipment can often be returned to service the same day, minimising business disruption.
Quality Parts
Only approved, rated replacement cords, plugs, and connectors used in all repairs.
Retest Included
All repaired items are retested immediately to confirm they meet AS/NZS 3760 requirements.
Industries We Serve
Trusted across New Zealand's key industries
FAQ
Cord Repairs FAQ
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