What Happens if an Appliance Fails a PAT Test?

By adminPAT Testing

Portable Appliance Testing (PAT) is a key part of workplace and property safety. But what happens if an appliance fails the test? Understanding the process can help businesses, landlords, and organisations respond correctly—and ensure both safety and compliance.

Why Appliances Fail PAT Testing

Appliances can fail a PAT test for several reasons:

  • Damaged Cables or Plugs – Frayed wires, exposed conductors, or broken plugs are common causes of failure.
  • Earth Continuity Issues – Class I appliances rely on a good earth connection. If this fails, the appliance is unsafe.
  • Insulation Resistance Problems – Poor insulation increases the risk of electric shock or fire.
  • Polarity or Wiring Faults – Incorrectly wired equipment can be dangerous.
  • Overuse or Wear – Appliances used heavily over time may deteriorate and fail testing.

What Happens Immediately After a Failure

When an appliance fails:

  1. Labeling – The tester will mark the item with a “FAIL” sticker to clearly indicate it’s unsafe.
  2. Removal from Use – The appliance should not be used until it is repaired or replaced.
  3. Documentation – Details of the failed appliance are recorded in the PAT test register, including the reason for failure.

Options for Failed Appliances

Once an appliance has failed, there are typically three options:

  1. Repair
    • Minor faults, such as a damaged plug or loose wire, can often be repaired on-site.
    • After repair, the appliance is retested to ensure safety.
  2. Replacement
    • If the appliance is beyond repair, old or irreparably damaged equipment should be replaced.
    • New appliances should be added to the PAT testing schedule.
  3. Decommissioning
    • Some appliances may be outdated or redundant. In these cases, safely dispose of the item and remove it from records.

Why Proper Handling Matters

Using a failed appliance is illegal and dangerous. Consequences of ignoring a failed PAT test include:

  • Electrical shock or fire
  • Legal liability under the Electricity at Work Regulations 1989
  • Insurance claims being invalidated
  • Damage to business reputation

Best Practices After a PAT Test

  • Act quickly – Repair or remove failed appliances immediately.
  • Keep records – Document actions taken to fix or replace the equipment.
  • Train staff – Make sure employees know not to use failed appliances.
  • Schedule retesting – Ensure repaired appliances are tested again before being put back into service.

Final Thoughts

A failed PAT test is a warning, not a punishment. It identifies equipment that could put people, property, and your business at risk. By handling failed appliances responsibly—repairing, replacing, or decommissioning—you ensure compliance, maintain safety, and prevent potentially costly accidents.

👉 Treat every PAT failure seriously—safety always comes first.