Essential PAT Testing Guidance

Portable Appliance Testing (PAT),  formally “In‑Service Inspection and Testing of Electrical Equipment”, is a simple, proven way to keep people safe and businesses compliant. By combining quick visual checks with targeted electrical tests, PAT helps you find faults before they cause shocks, fires, or costly downtime.

UK law expects duty‑holders to maintain electrical equipment so it does not give rise to danger. Two key pillars apply: the Electricity at Work Regulations 1989 and the Provision and Use of Work Equipment Regulations 1998 (PUWER), notably Regulation 4(2) (suitable maintenance) and Regulation 5 (suitability of equipment). While the law does not prescribe exact test intervals, it does require a sensible, risk‑based approach.

Ignite Facilities supports care providers, schools, and property managers with clear advice and hands‑on help. We plan risk‑based PAT regimes, complete the testing, label and log the results, and fold actions into your wider compliance plan - all with minimal disruption.

Understanding PAT Testing

PAT (In‑Service Inspection & Testing of Electrical Equipment) aims to keep equipment safe for continued use and to prevent danger. It is not just about “sticking a label on”; it is a practical process that scales from low‑risk offices to demanding kitchens and workshops.

PAT has three tiers of checks:

• User checks (basic visual by the user)
  Simple observations before use: damage to plugs or cables, signs of overheating, loose parts, or burning smells. Anyone can do this with a short briefing.
• Formal visual inspection (competent person, no testing)
  A more thorough look by trained staff or a contractor: opening the plug (if suitable), checking the fuse rating and cord grip, ensuring the correct plug top, strain relief, and casing integrity. No test instrument required.
• Combined inspection & test (visual + electrical testing)
  Adds instrument tests such as earth continuity, insulation resistance, polarity, and (where required) RCD operation. This level should be done by a competent person with calibrated equipment.

Legal context: The law does not set mandatory PAT intervals. Instead, the duty is to maintain equipment as necessary to keep it safe. PAT is a widely recognised method of showing you have assessed risk and taken proportionate steps. Records from PAT support audits, insurance, and incident investigations.

What Needs Testing? Class I vs Class II & Equipment Types

Understanding equipment class guides what you test and how.

• Class I (earthed)
  Protection relies on a protective earth. Examples: kettles, desktop PCs (PSU), vending machines, and many kitchen appliances. Tests: visual + earth continuity, insulation resistance, polarity, and functional checks.
• Class II (double‑insulated)
  Identified by the double‑square symbol. No protective earth; protection relies on reinforced insulation. Examples: most phone chargers, many power tools, some audio‑visual devices. Tests: visual + insulation resistance and polarity where applicable (no earth continuity test).

Equipment categories:

• Hand‑held (hairdryers, drills)
• Portable/moveable (microwaves, floor cleaners)
• Stationary (fridges, vending machines)
• IT equipment (computers, monitors, printers)
• Extension leads, detachable power cords, adapters, and RCDs - these must be included in the regime; they often fail.

New equipment: Generally safe on arrival, but always start with a user visual check. If the environment is tough or the item has been modified, do a formal visual before use.

Risk‑Based Frequency: Visual Checks vs Combined Testing

There is no single timetable that fits every site. The duty‑holder must assess risk and set sensible frequencies based on equipment type, environment, usage, movement, history, and the consequences of failure. Start with typical intervals, then adjust as your data grows.

Typical starting intervals (guide only)

Note: Low‑risk IT equipment in offices may only need a formal visual every 24 months and a combined test every ~60 months, provided the condition remains good.

How to refine intervals

• Review results: rising failure rates → shorten the interval; clean results → consider extending.
• Consider environment: heat, moisture, dust, vibration, public access, and frequent movement.
• Consider usage: how often, by whom, for what tasks; harsh handling demands tighter control.
• Track history: repeat offenders may need replacement, not more testing.

The goal is a living schedule that reflects real risk, not a fixed calendar.

Pass/Fail Criteria, Labelling & Record‑Keeping

Combined tests typically include earth continuity (Class I), insulation resistance, polarity, and functional checks. Thresholds vary by class and test method. Your competent person should apply the correct limits and safe test voltages for sensitive IT equipment.

While labels are not a legal requirement, most schemes use Pass/Fail labels with the next due date. Good practice is to label the appliance (or the plug if more visible) and keep the paperwork consistent.

If an item fails, remove it from service immediately. Decide whether to repair or replace. Dangerous items must not return to use until they pass a retest.

Keep clear records: asset ID, location, class, test results, defects, actions, and next due date. Over time, records reveal trends, inform buying choices, and justify frequency changes in audits.

Competence: In‑house vs Contractor

A competent person must carry out formal visuals and combined tests. Competence is not defined by law as a specific course, but widely recognised standards include City & Guilds 2377‑22 (or equivalent) plus practical experience. They must know how to test safely, interpret results, and decide when an item is unsafe.

In low‑risk settings, trained in‑house staff can handle user checks and some formal visuals. For combined testing, complex items, or higher‑risk environments (kitchens, workshops, construction), it is usually safer to use a qualified contractor with calibrated instruments and robust procedures.

Ignite Facilities can deliver both: we can train your team for user checks, provide contractor‑led PAT programmes, and integrate results into your wider compliance plan, giving you competence, consistency, and peace of mind.

Remedials & Cost Benchmarks

Common failures include damaged plugs and cables, crushed or stretched flexes, loose cord grips, wrong fuses, broken earth continuity (Class I), and low insulation resistance. Many faults are simple to fix: re‑terminating a plug, fitting the correct fuse, replacing a lead, or repairing a cracked casing. Others call for replacement.

Costs are often priced per item for combined inspection and test, sometimes with a lower rate after the first block of items. User checks cost little beyond staff time once trained. Value comes from preventing incidents, reducing downtime, and proving due diligence to insurers and regulators.

If you see frequent failures in one area, look upstream: poor storage, harsh handling, or unsuitable equipment. A small change, such as better cable management, strain relief, or switching a device to Class II, can pay for itself quickly.

Ignite Facilities offers transparent pricing, quick remediation, and the option to roll PAT into your planned maintenance and FM contracts for easier scheduling and fewer site visits.

How Ignite Facilities Can Help

We are a rapid‑response, trust‑focused M&E partner with deep experience in electrical compliance.

• Risk assessment and planning: we set sensible starting intervals by environment and use.
• In‑house or contractor‑led PAT testing: competent testers with calibrated instruments.
• Clear labelling and records: digital asset lists, results, and next‑due schedules.
• Remedials: on‑the‑spot plug/fuse fixes and fast repair/replacement routes.
• Schedule management: reminders and phased visits to minimise disruption.

We tailor our approach for care homes, schools, and small businesses - working neatly, communicating clearly, and keeping residents, pupils, and staff safe.

Conclusion

PAT testing is not a box‑ticking exercise. It is a risk‑based safety strategy that keeps people safe and your operation steady. Use risk assessments to set intervals, record the results, and adjust when conditions change. Focus on the items that move, heat, or are handled the most -  they fail first.

If you want a simple, robust regime that fits your site and budget, talk to Ignite Facilities. We will design and manage a PAT programme that is safe, compliant, and cost‑effective, and we will integrate it with your wider maintenance plan.