Many failed PAT items are not the result of a hidden electrical defect. A large proportion of problems can be identified during visual inspection before the test instrument is even connected.

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1. Damaged flexible cables

Cuts, crushing, fraying and exposed inner insulation are common reasons for taking equipment out of use. Damage can occur where cables are trapped under furniture, run through doorways or repeatedly coiled and uncoiled.

2. Cracked or damaged plugs

Plug casings can crack through impact or heavy use. Pins may become bent and cable entries can loosen.

3. Poor cord grips

The outer sheath of the cable should be securely held where it enters a plug or appliance. If the grip is loose, internal conductors may be exposed to strain.

4. Signs of overheating

Burn marks, discolouration or melted plastic can indicate overheating and should never be ignored.

5. Damaged appliance casings

Cracks, missing covers or exposed internal parts can make equipment unsafe even if an electrical measurement would otherwise appear acceptable.

6. Earth continuity problems

Class I equipment relies on a protective earth connection. Where appropriate testing identifies a poor or missing earth path, the item should not simply be returned to service.

7. Insulation problems

Electrical testing may identify deterioration that cannot be seen visually. The appropriate test depends on the equipment class and design.

8. Equipment used in the wrong environment

An appliance may be physically undamaged but unsuitable for wet, dusty or harsh conditions. HSE guidance says suitability for the environment should be considered as part of inspection.

What happens after a failure?

Equipment that fails maintenance checks should be removed from use until repaired by a competent person or replaced. Read our guide: What Happens If an Appliance Fails a PAT Test?

Why failure trends matter

Repeated failures can help a business adjust its inspection intervals or review how equipment is being used. This is one reason digital reporting can be valuable even though records are not automatically a legal requirement.

Official HSE guidance

See HSG107 for examples of faults that user checks and visual inspections should identify.

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