What Happens When Your PAT Test Fails? How to Prioritise Remedial Actions and Manage Compliance

When an appliance fails its Portable Appliance Test (PAT), it must be removed from service immediately, risk-assessed and prioritised for repair, replacement or safe disposal. Effective management of failed items protects users, supports regulatory compliance, and strengthens your overall electrical safety programme. 

This guide explains what happens when a PAT test fails, how to prioritise remedial work, and how to maintain compliance with help from Global Compliance UK. To book your next PAT visit or seek advice, simply use the contact page.

Why PAT Tests Fail

PAT failures occur when an appliance does not meet safety requirements during inspection or electrical testing. Failures can be classified into visual issues or measurable electrical faults. Common causes include:

• Damaged or frayed cables

• Cracked, loose or scorched plugs

• Loose wiring or incorrect fuse ratings

• Insulation breakdown inside the appliance

• High earth resistance on Class I appliances

• Overheating signs such as burn marks or melted plastic

• Exposed wiring or poorly repaired connectors

• Failure during leakage, polarity or continuity tests

Many faults develop over time due to wear and tear, transport damage, poor storage or misuse. Others are manufacturing defects that only become apparent when properly tested.

The key is to understand that a PAT failure is not random. It is a sign that the appliance now poses a potential shock or fire hazard and must not be used until remedial action is complete.

Immediate Steps to Take After a PAT Failure

Once an appliance fails, your first responsibility is to prevent further use. This protects users, reduces liability and creates a clear compliance trail. The following actions should happen straight away.

Remove the Appliance from Service

Failed equipment must be taken out of use immediately. The tester will normally attach a red fail label, but you should also ensure the appliance cannot accidentally be plugged in again. Many organisations implement a “quarantine area” for unsafe equipment.

Inform Relevant Staff or Departments

Let managers, supervisors, facilities teams or tenants know the equipment failed. This prevents confusion and ensures that staff do not unknowingly attempt to use it.

Record the Failure in Your Appliance Register

A failed PAT test must be recorded. Your register should include:

• Appliance name and ID

• Location

• Date of failure

• Reason for failure

• Recommended action

• Status such as “Awaiting repair”, “Replaced”, or “Disposed”

This documentation becomes part of your compliance evidence.

Assess the Severity of the Fault

Understanding whether the failure is minor or serious helps determine how quickly remedial action is required. For example:

• A blown fuse may be a quick fix

• A damaged cable may need repair by a competent person

• A failed insulation test may indicate serious internal damage

• A failed earth test on a metal appliance is an urgent safety issue

Once the severity is clear, you can begin planning the next steps.

How to Prioritise Remedial Actions

Not all PAT failures require the same level of urgency. Prioritisation ensures you manage risk effectively while avoiding unnecessary disruption or cost.

High-Priority Items

These items pose an immediate risk and should be repaired or replaced as soon as possible:

• Class I appliances with failed earth continuity

• Items showing burn marks, melting or exposed metal

• Appliances used in high-risk areas such as workshops or construction sites

• Equipment used frequently or by the public

• Appliances critical to operations or safety procedures

High-priority failures must remain out of service until repaired, retested and certified safe.

Medium-Priority Items

These have faults that may require attention but pose less immediate danger:

• Slight cable wear

• Damaged or loose plug casing

• Incorrect fuse rating

• Failure in a non-critical test

• Appliances used occasionally rather than daily

These items should be scheduled for repair within a reasonable timeframe, normally within 30 days.

Low-Priority Items

Some failures do not present active risk but must still be addressed:

• Cosmetic damage noted during visual inspection

• Older equipment reaching end of life

• Appliances already due for replacement

• Items rarely used or located in low-risk environments

Although lower in priority, these items must still be documented and managed responsibly.

The Remedial Action Process

Once priority levels are assigned, you can begin the remedial work required to restore safety and compliance.

Repairing the Fault

Many PAT test failures are repairable, including:

• Replacing incorrectly rated fuses

• Installing new plugs

• Repairing damaged cables

• Securing loose wiring

• Replacing worn components

Minor repairs can often be completed quickly by a competent electrician or maintenance professional.

Replacing the Appliance

If the equipment is severely damaged, fails multiple tests, or is no longer cost-effective to repair, replacement may be the best option. This is common with:

• Appliances with internal insulation breakdown

• Items with melted or warped casings

• Old equipment that fails repeatedly

• Devices where repairs would exceed the cost of a new appliance

Retesting the Appliance

After any repair, a full retest is essential. The appliance must pass all required PAT checks before it is returned to service. A retest ensures the repair has restored safety and verifies the appliance is safe to use again.

Updating Records and Returning to Service

Once an appliance passes its retest:

• Update your asset register

• Record the new pass date and next due date

• Label the appliance clearly

• Return it to the appropriate location

Keeping accurate documentation is not only best practice but also supports insurance and compliance requirements.

Managing Compliance After a PAT Test Failure

A PAT failure does not end with a retest. You must manage the incident within your wider compliance framework. This reduces the likelihood of repeat failures and keeps your electrical safety programme strong.

Maintain Clear and Traceable Records

Every stage of the failure, repair and retest must be documented. Your asset register should include:

• Failure date and reason

• All remedial actions

• Retest results

• Updated testing intervals

• Replacement date if applicable

This creates an audit trail that demonstrates responsible management.

Review Testing Intervals

If certain appliances fail frequently, consider adjusting your testing schedule. Increasing the frequency for high-risk or heavily used items can prevent faults developing into hazards.

Investigate Root Causes

Repeated failures may indicate:

• Poor user practice

• Inadequate storage

• Environmental hazards

• Substandard extension leads

• Overloaded sockets

• Equipment that is beyond its safe working life

Addressing the root cause of failures can reduce future testing costs and improve workplace safety.

Provide User Training

Some PAT failures are caused by:

• Poor handling

• Coiling cables too tightly

• Pulling plugs by the cable

• Using appliances in unsuitable environments

Short training sessions for staff or tenants can dramatically reduce faults and improve compliance.

Why a Structured Failure-Response System Matters

Many organisations focus heavily on the testing stage but overlook what happens after a failure occurs. However, the remedial process is equally important. A strong failure-response system:

• Reduces the risk of electric shock or fire

• Avoids downtime caused by unavailable equipment

• Demonstrates due diligence during audits

• Protects insurance validity

• Prevents future incidents by removing unsafe equipment

• Ensures compliance with the Electricity at Work Regulations

Handling a PAT failure correctly is not just safety best practice. It is a legal obligation and an essential part of managing electrical equipment.

How Global Compliance UK Supports the Remedial Process

Global Compliance UK provides a complete PAT testing service that includes clear guidance on failed items, support with risk prioritisation and advice on necessary remedial work. When you partner with us, you benefit from:

• Clear failure reports and explanations

• Support identifying high-risk issues

• Recommendations for repair or replacement

• Updates to asset registers and testing records

• Competitively priced testing programmes

• A risk-based approach tailored to your environment

• Services suitable for workshops, offices, rental properties, schools and more

To speak with our team or request a quote, visit the contact page.

Conclusion

A failed PAT test is not a setback; it is a signal to act. By removing unsafe equipment from service, prioritising remedial work and keeping accurate records, you maintain a safe environment and comply with electrical safety regulations. Once repairs or replacements are complete, a retest ensures the appliance is safe to use again. If you need support managing failed items, planning remedial work or building a risk-based PAT schedule, the team at Global Compliance UK is ready to help through our contact page.