A failed PAT test means the appliance did not meet the safety standard required for continued use.
When the tester found a fault that could be a visible damage, an electrical reading outside safe limits, or both.
Most failures result from minor issues a competent person can fix on-site within minutes.
What does it mean if an appliance fails a PAT test?
A failed result means the appliance did not pass the visual inspection or one of the electrical tests and to avoid any sudden accident that item must be removed from service immediately and either repaired or replaced before anyone uses it again.
Why Appliances Fail PAT Tests
Damaged Cables, Plugs, and Wiring
Frayed cables, cracked plug casings, loose connections, and exposed conductors account for more failures than any other cause. These faults develop through normal wear.
Most are repairable on-site like a competent tester can rewire a plug or fit a fuse in minutes, re-test, and return the appliance to service.
Earth Continuity and Insulation Resistance Failures
The earth continuity test confirms the earth wire in a Class I appliance provides a low-resistance path for fault current. A reading above (0.1 + R)Ω means the connection is broken or corroded. The insulation resistance test applies 500 V d.c. between live conductors and earthed metalwork. Readings below 1 MΩ (Class I) or 2 MΩ (Class II) indicate current leakage.
Incorrect Fuse Ratings and Overheating Signs
Appliances under 700 W require a 3 A fuse; above 700 W, a 13 A fuse. Incorrect fuses are among the most frequent failure causes and the easiest to correct. Burn marks and blocked ventilation indicate overheating and trigger an immediate fail.
| Failure Type | What the Tester Finds | Fixable On-Site? |
|---|---|---|
| Frayed or cut cable | Damage to sheath or conductors | Yes |
| Cracked plug | Broken plastic exposing wiring | Yes |
| Failed earth continuity | Resistance above (0.1 + R)Ω | Depends on cause |
| Failed insulation resistance | Below 1 MΩ or 2 MΩ | Usually no |
| Incorrect fuse | Wrong amperage | Yes |
| Overheating damage | Burn marks, melted plastic | Usually no |
What is the most common reason for PAT test failure?
Damaged cables and plugs cause more failures than any other fault. Frayed leads, cracked casings, and loose connections develop through daily wear and are found during the visual inspection.
Why would a kettle fail a PAT test?
Kettles commonly fail earth continuity because the detachable base connector corrodes or the earth connection loosens. An incorrect fuse rating is the other frequent cause.
Interpreting readings correctly on different appliance types, with a live PAT tester in front of you, is where formal training makes the difference. PAT Training Now runs 1-day courses at over 21 UK locations, including hands-on practice with real test equipment. Find your suitable Course dates on Pat Venue Finder.
A Failed Result Doesn’t Always Mean a Faulty Appliance
Calibration Issues and Wrong Test Equipment
PAT testers require regular calibration. An uncalibrated instrument can fail an appliance that would pass on a properly calibrated machine.
When the Wrong Test Is Applied to the Appliance Class
Appliances with EMI filters — computers, power tools, televisions — often fail the standard insulation resistance test because 500 V d.c. triggers internal components. These require a substitute leakage current test. Long extension leads present a similar issue — earth continuity resistance rises with cable length, not because the earth is faulty.
Can an appliance fail a PAT test and still be safe?
Yes. Uncalibrated equipment, the wrong test for the appliance class, or a long cable producing a high reading can generate false fails. A competent tester identifies these and applies the correct method.
Why did my computer fail the PAT test?
Computers contain EMI filters that trigger the standard insulation resistance test. A competent tester applies a substitute leakage current test instead. The IET Code of Practice covers correct test selection.
What to Do After an Appliance Fails
Label It and Take It Out of Service
Attach a “Failed — Do Not Use” label. Unplug it and move it somewhere it cannot be used by mistake.
Labelling is not a legal requirement in the UK but is standard practice. In Ireland, it is a legal requirement.
Repair or Replace: How to Decide
Minor faults — a damaged plug, blown fuse, frayed cable are repairable on-site. Failed insulation or corroded earth connections may cost more to fix than the appliance is worth.
If repair exceeds half the replacement price, replace it.
Re-Testing After Repair
A repaired appliance must pass a full PAT test before anyone uses it. The original fail stands until a new pass is recorded. This is the step most people skip.
Can a failed appliance be repaired and re-tested?
Yes. Minor faults are repaired on-site and re-tested immediately. The appliance returns to service only after it passes the re-test.
Do I have to throw away an appliance that fails PAT testing?
No. Most failures result from minor faults a competent person can fix. Only appliances with irreparable damage or where repair cost exceeds replacement cost need disposal.
Who can repair a failed PAT tested appliance?
A competent person with sufficient knowledge and skill. The Electricity at Work Regulations 1989 do not require a qualified electrician specifically, but the person must understand the fault and the correct repair method.
Competence means training. PAT Training Now’s 1-day PAT Testing Courses covers the IET 5th Edition Code of Practice and results in a UKRS-accredited Certificate of Competence. Details at pat-training-now.co.uk/open-pat-courses.
What to Document After a PAT Failure
What Your Failure Record Should Include
Every failure record should contain the appliance ID, location, test date, tester name, fault found, action taken, and re-test result. Record actual measured readings — not just pass or fail — to track degradation over time.
How Long to Keep PAT Records
No statutory minimum exists. The HSE Memorandum of Guidance advises records be kept throughout the working life of the equipment. Keep records for the full working life plus five years after disposal. Claims under the Limitation Act 1980 can run up to three years from the date of knowledge.
Do I need to keep records of PAT test failures?
No specific legal requirement exists, but the HSE recommends it and insurers expect it. A record is the only proof that testing was carried out and failures were acted upon.
How long should PAT testing records be kept?
Keep records for the full working life of the appliance plus at least five years after disposal. Claims under the Limitation Act 1980 allow up to three years from the date of knowledge.
Legal and Insurance Risks of Ignoring a Failed PAT Test
Who’s Responsible: Employers, Landlords, and Duty Holders
The duty holder — usually the employer or landlord — bears responsibility. The Electricity at Work Regulations 1989, the Health and Safety at Work Act 1974, and PUWER all require electrical equipment to be maintained to prevent danger. Fines are unlimited for serious breaches and custodial sentences are possible.
What Happens to Your Insurance If You Ignore Failures
Most employer’s liability and public liability policies require evidence of electrical maintenance. If someone is injured by a failed appliance and no action was taken, the insurer has grounds to refuse the claim. A PAT register showing the failure and re-test result is your due diligence evidence.
Is it illegal to use an appliance that failed PAT testing?
No specific law makes it an offence. Knowingly using unsafe equipment breaches the Electricity at Work Regulations 1989 and exposes the duty holder to prosecution and civil liability.
Can I be fined for not PAT testing?
PAT testing is not a named legal requirement. Fines apply when the duty to maintain safe equipment is breached. The HSE can impose unlimited fines under the Health and Safety at Work Act 1974.
Does insurance cover damage from faulty appliances?
Most policies require evidence of electrical maintenance. If a known failure was ignored and no records exist, the insurer may refuse the claim under employer’s and public liability cover.
No electrical background is required. PAT Training Now has trained people from facilities management, property letting, schools, and small businesses over 18 years. The 1-day course includes theory and practical assessment, with a PAT tester on loan. Dates at pat-training-now.co.uk/events/month.
Conclusion
A failed PAT test is the system doing its job. The appliance gets labelled, removed from service, and repaired or replaced. The problems start when failures are ignored or records are not kept.
PAT Training Now runs the 1-day course face-to-face at over 20 locations (£195 + VAT), online via Zoom (£145 + VAT), or on-site for groups. All formats follow the IET 5th Edition syllabus and result in the same UKRS-accredited certificate.
