The PAT testing engineer is packing up their kit. They hand you the report. And there it is — a big red FAIL next to one of your appliances.
Your first thought is probably "how much is this going to cost me?" But here's the thing most people don't realise: not every PAT test failure means you need to buy new equipment.
In fact, many failures can be fixed in minutes for a few pounds. Some aren't even electrical faults — they're administrative issues that are quick to resolve.
This guide breaks down exactly what different types of failure mean, what your options are, and how long you have to sort things out — no panic required.
The Three Types of PAT Test Failure
PAT testing engineers categorise failures into three main groups. Knowing which category your appliance falls into determines what happens next.
1. Visual Failures (Most Common)
A visual failure means the engineer spotted something wrong just by looking at the appliance. This accounts for roughly 80–90% of all PAT test failures. Common causes include:
- Damaged cable — frayed, cut, or crushed power cord
- Faulty plug — cracked casing, bent pins, or a missing fuse
- Overheating signs — discolouration or melting around the plug or cable
- Missing parts — cable clamp missing, screws loose
- Unauthorised repairs — tape on cables, incorrect fuse ratings
What to do: Most visual failures are repairable. A new plug costs about £1–2 and takes 5 minutes to fit. A replacement cable might be £5–15. Even broken appliances can often be fixed for less than the cost of replacement.
2. Earth Bond Failures
This test checks that the earth connection between the plug and any exposed metal parts of the appliance is continuous and has low resistance. A failure here means the earth path isn't working properly, which is a safety concern.
Earth bond failures typically affect Class I appliances — things with metal casings like kettles, toasters, heaters, and power tools.
What to do: Earth bond failures can sometimes be traced to a loose earth wire inside the plug. Have an electrician check and retest. If the internal wiring is the problem, the appliance may need replacing.
3. Insulation Failures (Most Serious)
An insulation failure means the electrical insulation inside the appliance has broken down. Current is leaking where it shouldn't be. These are the most serious type of failure because they present a real risk of electric shock.
What to do: Insulation failures almost always mean the appliance needs to be replaced. Do not continue using it. If the engineer has tagged it as "Danger — Do Not Use," take that seriously.
What Happens After a Fail?
When an appliance fails, the engineer will usually do one of three things:
| Action | When It's Used |
|---|---|
| Remove from service | Appliance is taken away or locked in a cupboard for safety |
| Red "Fail" label | Appliance stays in place but is clearly marked as failed |
| Verbal advice | Minor issue that can be fixed and retested on-site immediately |
Whatever the outcome, the failed item will be recorded on your PAT test certificate with a clear reason for the failure.
How Long Do You Have to Fix Failed Items?
This is one of the most common questions business owners ask. The answer depends on the severity:
- Immediate danger (insulation failure) — cease using the appliance right away. No grace period.
- Minor fail (damaged plug, frayed cable) — fix before next use or within a reasonable timeframe. Most engineers recommend within 28 days.
- Administrative issue (wrong fuse, poor labelling) — fix when convenient, but before the next scheduled test.
There's no fixed legal timeframe for repairing failed items. The key requirement is that you're not using unsafe equipment. Document your repair plan and keep records — that demonstrates your compliance approach if the HSE ever asks.
Should You Repair or Replace?
Here's a quick decision guide:
| Scenario | Cost to Fix | Recommendation |
|---|---|---|
| Damaged plug | £1–2 | Repair |
| Frayed cable | £5–15 | Repair if appliance is otherwise fine |
| Earth bond failure | £20–50 (electrician) | Try repair first; replace if expensive item |
| Insulation failure | Usually not cost-effective | Replace |
Can You Retest a Failed Appliance?
Yes. If you've repaired a failed item, you can have it retested. Most PAT testing companies will offer reduced retest fees — you're only paying for the one item, not a full site test.
Some engineers will retest immediately if the fix is quick and they're still on-site. Others may ask you to book a separate visit.
What About Failed Appliances from Previous Tests?
If you've inherited a PAT testing regime from a previous engineer or business owner and find failed items that were never dealt with, the same rules apply:
- Check if the appliance is still in use (many "failed" items are quietly put back into service)
- Assess the severity of the failure from the paperwork
- Either repair, retest, or dispose of each failed item
- Update your records to show what action was taken
Preventing Future Failures
The best way to deal with PAT test failures is to avoid them in the first place. Here are practical steps any business can take:
- Train staff — teach them to spot damaged cables and plugs during daily use
- Replace on sight — if a cable is frayed, replace it then, not when the PAT tester arrives
- Buy quality — cheap appliances fail PAT tests at much higher rates
- Keep records — track which items fail and why, so you can spot problem patterns
- Use cable tidies — trailing cables that get walked on or trapped in furniture are the number one cause of PAT failures in offices
Final Thoughts
A failed PAT test is not a disaster. For most businesses, the failure rate is typically 5–15% of tested items, and the vast majority are simple visual issues that cost a few pounds to fix. If your failure rate is much higher than 15%, that's a sign you might be buying poor-quality equipment or not maintaining it properly between tests.
If you're based in Nottingham and need a PAT test — or need advice on failed items from a recent test — we can connect you with local City & Guilds 2377 certified engineers who can help. Get a free quote or call 0333 038 2842.