Portable Appliance Testing (PAT) is essential for ensuring workplace and property safety. During testing, some appliances pass with no issues, while others fail—sometimes unexpectedly. Knowing which appliances are most likely to fail can help businesses, landlords, and facility managers stay proactive, safe, and compliant.
1. Kettles and Kitchen Appliances
Why they fail:
- Frequent use and exposure to water and steam
- Frayed cords or damaged plugs
- Internal component faults
Tip: Inspect regularly and replace cords or plugs at the first sign of wear.
2. Extension Leads and Power Strips
Why they fail:
- Overloading multiple devices
- Cables becoming twisted or damaged
- Loose connections in plugs or sockets
Tip: Avoid daisy-chaining extension leads and ensure leads are rated for the appliances used.
3. Laptops, Monitors, and Office Electronics
Why they fail:
- Power adapters and chargers can wear over time
- Loose or damaged connectors
- Internal electrical faults from heavy daily use
Tip: Visual checks before use can catch wear early, and damaged adapters should be replaced immediately.
4. Portable Heaters and Fans
Why they fail:
- High heat output can damage internal wiring
- Cables may get pinched or stepped on
- Fans can accumulate dust, affecting insulation
Tip: Regular cleaning and careful handling reduce failure rates.
5. Vacuum Cleaners and Cleaning Equipment
Why they fail:
- Rough handling during cleaning
- Twisted or pinched cords
- Overheating due to blocked filters or motors
Tip: Inspect cords and plugs regularly, and maintain appliances according to manufacturer guidelines.
6. Power Tools on Construction Sites
Why they fail:
- Harsh environments with dust, moisture, and heavy impact
- Overuse by multiple workers
- Damage to cables or insulation
Tip: Frequent PAT testing and visual inspections are essential in high-risk environments.
Why Knowing Common Failures Matters
- Prioritise High-Risk Equipment: Focus inspections and testing where faults are most likely.
- Prevent Accidents: Early detection prevents shocks, fires, or equipment damage.
- Cost Savings: Repairing appliances is often cheaper than replacing them after a failure.
- Compliance and Insurance: Ensures you meet legal obligations and maintain insurance coverage.
Final Thoughts
While almost any appliance can fail a PAT test, kettles, extension leads, office electronics, heaters, cleaning equipment, and power tools are among the most common culprits. Understanding why these items fail helps organisations stay proactive, reduce risks, and maintain a safe environment.
👉 Regular PAT testing, combined with visual inspections and proper handling, keeps both people and equipment safe—reducing downtime, costs, and liability.