What Happens If an Appliance Fails a PAT Test? — Risks and Next Steps

Electrical safety is one of the cornerstones of a safe workplace. Whether you’re running an office, managing a warehouse, or renting out property to tenants, electrical appliances are everywhere—and keeping them safe is not optional. Portable Appliance Testing, more commonly known as PAT testing, provides the reassurance that your equipment is in good working order.

But what if something fails? What happens if a kettle, computer, extension lead, or other piece of equipment doesn’t pass the test?

In this blog, we’ll take a detailed look at what happens when an appliance fails a PAT test, the risks you face if you ignore it, and the steps you should take to stay compliant and safe. We’ll also explore how Global Compliance can support you with expert PAT testing and practical safety solutions.

What Is PAT Testing and Why Is It Important?

PAT testing is the inspection and testing of electrical equipment to ensure it is safe to use. It typically involves two stages:

1. Visual inspection – checking plugs, leads, sockets, and casings for signs of wear or damage.

2. Electrical testing – using specialist instruments to check insulation resistance, earth continuity, polarity, and leakage current.

This process provides evidence that an appliance is safe, reducing the risk of electric shock, fires, and injuries caused by faulty equipment.

Legal Background

While the law doesn’t specifically say PAT testing is mandatory, the Electricity at Work Regulations 1989 do require employers, landlords, and duty holders to ensure electrical equipment is maintained to prevent danger. PAT testing is widely recognised as one of the most effective ways to achieve this.

Failing to test or ignoring failed appliances could mean non-compliance with health and safety duties, with possible consequences ranging from fines to invalidated insurance claims.

Why Do Appliances Fail PAT Tests?

Before we cover the consequences, it’s useful to understand why items fail in the first place. Common reasons include:

• Damaged power cords – frayed or exposed wires.

• Cracked or broken casings – especially around plugs and sockets.

• Poor earth continuity – where the protective earth connection isn’t functioning.

• Insulation resistance issues – meaning electricity could leak and cause shocks.

• Overheating signs – scorch marks or melting.

• Incorrect fuses – either too weak or too strong for safe operation.

Some failures are minor and fixable. Others point to deeper faults where replacement is the only safe option.

The Risks of Using Failed Equipment

When an appliance doesn’t pass its PAT test, the risks extend far beyond inconvenience. They can be grouped into safety, legal, financial, and reputational categories.

Safety Risks

• Electric shock – faulty insulation or damaged cables can deliver life-threatening shocks.

• Fires – frayed wiring or overheating components can ignite.

• Injury or death – the most serious risk of ignoring test failures.

Legal Risks

• Continuing to use failed appliances may breach your duty of care under UK safety law.

• Landlords risk prosecution if tenants are injured by unsafe electrical items.

• Businesses may face enforcement action from the HSE (Health and Safety Executive).

Insurance Risks

• Many insurers will refuse claims if a fire or injury is linked to unsafe appliances that failed PAT testing.

• You could be liable for damages and compensation costs.

Business Risks

• A serious electrical incident can shut down operations.

• Negative publicity and damaged reputation can take years to recover from.

What To Do When an Appliance Fails a PAT Test

So, your appliance has failed—what now? Here’s a step-by-step guide:

Step 1: Label Clearly

Apply a “Do Not Use” or “Failed PAT Test” label to the appliance. This alerts anyone nearby that it’s unsafe.

Step 2: Remove from Service

Unplug the appliance and move it to a safe, designated area for faulty equipment. Never leave failed items plugged in.

Step 3: Assess: Repair or Replace

• Repairable faults: Loose wires, damaged plugs, or incorrect fuses may be fixed.

• Irreparable faults: Extensive internal damage, persistent insulation failures, or outdated appliances are often cheaper and safer to replace.

Step 4: Engage a Qualified Professional

If repair is an option, only use a qualified electrician or technician. Repairs should comply with the IET Code of Practice for In-service Inspection and Testing of Electrical Equipment.

Step 5: Retest Before Use

Once repaired, the appliance must undergo another PAT test. It can only be returned to service if it passes.

Step 6: Document Everything

Maintain accurate records including:

• Date of failure.

• Type of fault identified.

• Repair or replacement details.

• Retest results.

This protects you during audits, inspections, or insurance claims.

Examples of Common Failures and Fixes

Let’s look at a few scenarios you might encounter:

Issue	Repair Options	Notes
Damaged plug casing	Replace plug	Low-cost, quick fix.
Incorrect fuse fitted	Replace with correct rating	Must match manufacturer guidance.
Cable insulation worn	Replace cable	Essential to prevent shocks.
Appliance overheating	Investigate internal fault	May be more cost-effective to replace.
Earth continuity fail	Repair plug/cable or replace appliance	Safety critical—do not ignore.

Preventing PAT Test Failures

The best way to handle a PAT test failure is to avoid it in the first place. Preventive measures include:

Regular Visual Inspections

Staff should check appliances for visible wear and tear—loose wires, scorch marks, broken sockets—before use.

Scheduled Maintenance

Routine servicing and cleaning extends the life of appliances and reduces failures.

Staff Awareness

Employees should know how to use equipment safely and report issues early.

Good Record-Keeping

Keep logs of tests, faults, repairs, and replacements. This supports compliance and makes testing cycles smoother.

Use of Quality Equipment

Investing in well-made appliances reduces long-term risk and cost.

What If You Ignore a PAT Test Failure?

Ignoring a failed PAT test is never a safe option. Consequences can include:

• Serious injury: staff, tenants, or visitors could be harmed.

• Prosecution: non-compliance with UK safety regulations can bring fines and even custodial sentences.

• Insurance loss: insurers may void claims, leaving you liable for damages.

• Reputation damage: businesses that cut corners on safety lose trust fast.

The bottom line? Never ignore a PAT failure. Always take action.

How Global Compliance Can Help

At Global Compliance, we specialise in helping businesses and landlords stay safe, legal, and worry-free. Our PAT testing services include:

• Thorough visual and electrical testing.

• Clear pass/fail labelling for each item.

• Advice on repair versus replacement.

• Comprehensive documentation for compliance records.

• Ongoing support to manage testing schedules.

Whether you have one property or multiple sites, we tailor our services to your needs. To arrange professional support:

• Phone: 0330 100 5341

• Email: info@global-compliance.co.uk

Frequently Asked Questions (FAQs)

Is PAT testing legally required?Not directly, but the law requires electrical equipment to be safe. PAT testing is the best way to prove compliance.

Can I repair a failed appliance myself?No—unless you are qualified. Only trained professionals should carry out electrical repairs.

Do I need to replace everything that fails?Not always. Some minor issues (e.g. a damaged plug) can be repaired cost-effectively.

How often should appliances be tested?It depends on use and environment. High-risk equipment (construction tools, catering appliances) may need more frequent testing.

Conclusion

A failed PAT test is not the end of the world, but it is a clear signal that action is needed. The risks of ignoring it are too high—electric shock, fire, prosecution, insurance issues, and reputational damage.

By following the right steps—labelling, removing from service, repairing or replacing, retesting, and documenting—you protect your staff, tenants, and business. Better still, preventive measures such as regular checks and proper maintenance can reduce failures altogether.

With Global Compliance, you don’t have to manage this alone. Our expert team makes the process smooth, professional, and fully compliant, giving you peace of mind.

Stay safe, stay compliant, and let us handle the details.