Discovering that an appliance has failed a PAT test can be alarming, but it should be viewed positively — you've identified a potential electrical hazard before it caused a fire, an injury, or worse. The key is knowing what to do next.
Common Reasons for PAT Test Failures
- Damaged cable — cuts, fraying, kinks, or exposed conductors
- Cracked or damaged plug casing
- Incorrect fuse rating in the plug
- Failed earth continuity (particularly dangerous in metal-bodied appliances)
- Low insulation resistance — indicating degraded or damaged internal wiring
- Burn marks or evidence of overheating on the appliance or cable
- Liquid damage or ingress
- Missing or damaged earthing connections
Immediate Steps After a Failure
- Remove the appliance from service — do not continue to use it
- The engineer will apply a red FAIL label to the appliance
- Record the failure in your equipment register
- Arrange repair or replacement promptly
- Retest the appliance after any repair before returning it to service
Can Failed Appliances Be Repaired?
Many common failure causes are simple and inexpensive to fix. A damaged cable can be replaced; a cracked plug can be swapped; an incorrect fuse can be changed. More serious internal electrical faults may make repair uneconomical, particularly for lower-value appliances. After any repair, the appliance must be retested before being returned to service.
High Failure Rates: A Warning Sign
If a significant number of appliances fail in the same testing round, this may indicate a systemic problem — such as an issue with your electrical supply quality, a procurement problem (buying poor-quality appliances), or environmental conditions that are accelerating equipment degradation. Our engineers can advise on likely causes and corrective actions.
