A recent investigation by consumer organisation Which? has found potentially dangerous phone chargers being sold through major online marketplaces and well-known retail websites.
Of the 15 chargers tested, nine reportedly presented serious electric shock risks, while eight posed potential fire or explosion hazards.
Some failed because internal components were positioned too closely together, insulation was inadequate, plug pins did not meet the expected standard or the charger could not withstand high-voltage testing.
One apparent counterfeit Apple charger reportedly began making arcing noises after only ten seconds. When it was opened, modelling clay was found inside, apparently added to make the charger feel heavier and more substantial.
The investigation is another reminder that electrical safety cannot be taken for granted simply because an item is new, looks professional or was purchased from a familiar website.
It also demonstrates why PAT testing should involve far more than connecting equipment to a tester and recording a result.
New equipment is not automatically safe
There is a common assumption that newly purchased electrical equipment does not need to be checked because it has not yet had time to become damaged.
In reality, electrical equipment can be unsafe from the moment it arrives.
Possible problems include:
- Manufacturing defects.
- Counterfeit products.
- Incorrectly sized plug pins.
- Damaged insulation.
- Loose components.
- Poor-quality mouldings.
- Incorrect or misleading markings.
- Missing manufacturer or importer information.
- Damage caused during storage or delivery.
A new charger may therefore require attention before it is introduced into a workplace, particularly where its origin or quality is uncertain.
PAT testing programmes should not focus only on older appliances. They should form part of a wider system for controlling all electrical equipment used at work.
PAT testing begins with visual inspection
The visual inspection is one of the most important parts of in-service inspection and testing.
Many electrical defects can be identified without switching on a PAT tester.
A competent person examining a phone charger may notice:
- Cracks or gaps in the casing.
- Loose or distorted plug pins.
- Missing pin insulation.
- Signs of overheating.
- Scorching or discolouration.
- Poor-quality labelling.
- Damaged cables.
- Loose connectors.
- Unusual rattling.
- Incorrect fuse arrangements.
- Suspicious branding.
- Missing manufacturer details.
- A lack of traceability information.
A charger showing any of these warning signs should not simply be tested and returned to service.
It may need to be quarantined, replaced or referred to the person responsible for electrical safety.
This is why effective PAT testing depends on the knowledge and judgement of the person carrying it out.
PAT testing is not just about the test instrument
The term “PAT testing” is commonly used, but the work is more accurately described as in-service inspection and testing of electrical equipment.
The test instrument is only one part of the process.
A proper inspection programme should consider:
- The type of equipment.
- How it is constructed.
- Where it is used.
- Who uses it.
- How often it is moved.
- Whether it is exposed to damage.
- The environment in which it operates.
- The quality and source of the equipment.
- Previous inspection results.
- Any reports of overheating or malfunction.
A charger used occasionally at an office desk may present a different level of risk from one used in a hotel bedroom, workshop, school, care setting or shared accommodation.
The frequency and extent of inspection should reflect those circumstances.
Cheap chargers should receive closer attention
Low price does not automatically mean that a charger is unsafe.
However, unusually cheap branded equipment, unknown manufacturers and untraceable marketplace sellers should raise questions.
A competent inspector should be alert to products that:
- Appear to imitate a well-known brand.
- Cost far less than the genuine equivalent.
- Have unclear manufacturer information.
- Have no identifiable UK importer.
- Carry poor-quality or inconsistent markings.
- Feel unusually light, loose or poorly assembled.
- Become excessively hot in normal use.
- Produce buzzing, crackling or arcing sounds.
Where there is reasonable doubt about the safety of a low-cost charger, replacement is normally the sensible option.
The cost of a reputable replacement is insignificant compared with the consequences of electric shock, fire or damage to expensive equipment.
Employee-owned chargers need to be managed
Phone chargers are frequently brought into workplaces by employees.
This can make electrical safety management more difficult because the employer may not know:
- Where the charger was purchased.
- Whether it is genuine.
- How old it is.
- Whether it has previously overheated.
- Whether it has been damaged.
- Whether it has been subject to a recall.
- Whether it is suitable for the device being charged.
Employers may decide to include personally owned chargers within their inspection programme or restrict their use.
Another option is to provide approved workplace chargers and require employees to use those instead.
The important point is that employee-owned electrical equipment should not be ignored simply because it does not belong to the business.
If equipment is being used at work, it may still need to be managed as part of the organisation’s electrical safety arrangements.
Competence matters
The Which? findings show why organisations should not treat PAT testing as an unskilled administrative exercise.
A competent PAT tester needs to understand:
- Electrical equipment classes.
- Plug and fuse requirements.
- Visual inspection techniques.
- Appropriate electrical tests.
- Test limitations.
- Common signs of damage.
- Risk-based inspection frequencies.
- Equipment records and labelling.
- When equipment should be removed from service.
- When specialist advice is required.
A person who has only been shown how to press the test button may miss important warning signs.
By contrast, someone who understands the full inspection process is better equipped to identify suspicious equipment, make sensible decisions and communicate concerns to the duty holder.
PAT testing supports better purchasing decisions
Inspection records can also help organisations identify patterns.
For example, repeated failures involving the same type of charger, supplier or manufacturer may indicate a wider purchasing problem.
The business can then:
- Stop purchasing that product.
- Change supplier.
- Replace similar units.
- Issue guidance to employees.
- Review whether personally owned chargers should be permitted.
- Check for recalls or safety notices.
PAT testing therefore provides useful information beyond the individual appliance.
It can help an organisation improve procurement, reduce repeat failures and remove poor-quality equipment from the workplace.
A pass label should never replace good judgement
Equipment should only be returned to service when the person carrying out the inspection is satisfied that it is suitable for continued use.
Where a charger looks suspicious, shows signs of overheating, has damaged pins or lacks basic traceability, the correct decision may be to remove it from service.
A competent inspector should not ignore visible concerns simply because an electrical test result appears acceptable.
Likewise, equipment should not receive a pass label where the inspector has unresolved concerns about its condition or suitability.
PAT testing combines inspection, testing and professional judgement.
All three are important.
What should employers do?
Employers and duty holders should consider the following steps:
- Purchase chargers and power supplies from reputable suppliers.
- Avoid unbranded or suspiciously cheap electrical products.
- Include chargers within the electrical equipment management programme where appropriate.
- Inspect new equipment where there is a risk of damage, poor quality or counterfeit supply.
- Provide staff with a simple method of reporting overheating or damaged chargers.
- Remove damaged or suspicious equipment from use immediately.
- Keep clear inspection and testing records.
- Ensure the person carrying out the work has received suitable training.
- Review whether employee-owned chargers should be restricted or inspected.
- Replace questionable chargers rather than taking unnecessary risks.
The role of PAT testing training
Effective PAT testing training should teach more than how to use a test instrument.
Learners should understand how to inspect equipment, select suitable tests, recognise defects and make safe decisions.
They should also understand when equipment must be removed from service and how to explain their findings to an employer or duty holder.
The recent charger investigation reinforces a simple point:
Electrical safety depends on competent inspection, appropriate testing and informed judgement.
As more low-cost electrical products enter workplaces through online marketplaces, the ability to recognise poor-quality, damaged and suspicious equipment is becoming increasingly important.
A well-trained PAT tester can play a valuable role in preventing unsafe equipment from remaining in use.
Learn how to carry out PAT testing correctly
GetTesting’s one-day PAT Testing Course is designed to give learners the practical knowledge needed to inspect and test electrical equipment safely.
The course covers visual inspection, equipment classes, electrical testing, record keeping, risk assessment and the practical decisions testers need to make in real workplaces.
It is suitable for people who need to carry out PAT testing for employers, landlords, schools, facilities, workshops, charities and other organisations.
View upcoming PAT Testing Course dates and locations.
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