Discovering that one or more of your appliances has failed a PAT test can be alarming, but it's actually a positive outcome — you've identified a safety hazard before it causes harm. Here's exactly what you need to do when an appliance fails.
What Causes an Appliance to Fail?
Appliances fail PAT tests for a variety of reasons. Common failure causes include damaged cables (cuts, fraying, or exposed wires), damaged or cracked plugs, poor or absent earth continuity (especially dangerous in metal-bodied appliances), low insulation resistance (indicating degraded or damaged insulation), incorrect fuse rating, burn marks or evidence of overheating, and liquid damage.
Immediate Steps When an Appliance Fails
- Remove the appliance from service immediately — do not continue to use it
- Apply a clear FAIL label (our engineers do this during testing)
- Record the failure in your equipment register
- Arrange repair or replacement as soon as possible
Can a Failed Appliance Be Repaired?
Many faults that cause PAT test failures are simple and inexpensive to repair. A damaged cable can be replaced. A cracked plug can be changed. A blown fuse can be swapped for the correct rating. More serious electrical faults inside the appliance may make repair uneconomical, in which case replacement is the better option. After any repair, the appliance should be retested before being put back into service.
After Repair: Retest Before Use
This step is critical and often overlooked. Once an appliance has been repaired, it must be retested before being returned to service. Our engineers can carry out retest visits for repaired equipment, or in some cases advise on simple self-testing checks for straightforward repairs.
Dealing With High Failure Rates
If a significant proportion of your appliances fail a PAT test, this may indicate a wider problem — potentially with your electrical supply, your equipment procurement practices, or the condition of your premises. Our engineers can advise on the likely causes of multiple failures and recommend steps to reduce future failure rates.
