Top Mistakes Businesses Make with PAT Testing (And How to Avoid Them)

By adminPAT Testing

Portable Appliance Testing (PAT) is a key component of workplace safety, helping businesses reduce risks from electrical appliances. However, many organisations make common mistakes that can compromise safety, compliance, and efficiency. Knowing what to avoid ensures your PAT testing program is effective and reliable.

1. Skipping PAT Testing Altogether

The Mistake: Some businesses assume that PAT testing isn’t mandatory and neglect it entirely.

Why It’s a Problem:

  • Puts employees, clients, and visitors at risk of electric shocks or fire.
  • Can invalidate insurance claims in the event of an accident.
  • Demonstrates a lack of compliance with the Electricity at Work Regulations 1989.

How to Avoid It:

  • Implement a regular PAT testing schedule for all electrical appliances.
  • Include all high-use, high-risk, and portable equipment.

2. Relying Solely on Visual Inspections

The Mistake: Believing a visual check is enough to confirm an appliance is safe.

Why It’s a Problem:

  • Many faults, such as internal wiring issues or insulation failure, are not visible.
  • Can lead to false confidence and overlooked hazards.

How to Avoid It:

  • Combine visual inspections with full PAT testing using qualified testers and calibrated equipment.

3. Using Untrained Staff to Carry Out PAT Testing

The Mistake: Assigning PAT testing to staff without proper training.

Why It’s a Problem:

  • Incorrect testing can miss faults, putting people at risk.
  • May result in failed audits or non-compliance with health and safety regulations.

How to Avoid It:

  • Ensure testers are competent, trained, and familiar with the latest standards.
  • Consider professional PAT testing services for larger workplaces or complex equipment.

4. Failing to Keep Accurate Records

The Mistake: Conducting PAT tests but not recording results properly.

Why It’s a Problem:

  • No proof of compliance during audits or inspections.
  • Difficult to track trends, repeated failures, or appliance history.
  • Insurance claims may be affected in the event of an accident.

How to Avoid It:

  • Maintain detailed, organised records of tests, failures, repairs, and replacements.
  • Digital record-keeping can streamline audits and trend analysis.

5. Ignoring Follow-Up Actions on Failed Appliances

The Mistake: Testing appliances but leaving failed items in use.

Why It’s a Problem:

  • Directly increases the risk of accidents.
  • Undermines the purpose of PAT testing entirely.

How to Avoid It:

  • Immediately repair, replace, or remove any failed appliance.
  • Clearly label failed items and update your records accordingly.

6. Not Testing Frequently Enough

The Mistake: Setting long intervals between tests without considering appliance usage or environment.

Why It’s a Problem:

  • High-use or high-risk equipment can deteriorate faster, leaving hazards undetected.
  • Compliance may be questioned during inspections.

How to Avoid It:

  • Implement a risk-based testing schedule:
    • Annual testing for most office appliances.
    • More frequent testing for high-risk environments, such as construction sites or schools.

Final Thoughts

PAT testing is a critical element of workplace safety, but mistakes are common. By testing regularly, using trained staff, keeping accurate records, and acting promptly on failures, businesses can avoid costly accidents, maintain compliance, and protect staff and visitors.

👉 A well-managed PAT testing program isn’t just about ticking boxes—it’s about creating a safer, smarter, and more responsible workplace.