Electrical faults are one of the leading causes of workplace fires and electrocution incidents in Australia. Test and tag is the process of visually inspecting, electrically testing and labelling portable appliances to confirm they are safe to use. It protects workers, satisfies WHS Act obligations and provides documented proof of compliance when a regulator or insurer asks for it.
This guide is for electricians, safety officers, facilities managers and site supervisors who need a repeatable procedure for testing and tagging portable electrical equipment on construction sites, in warehouses or across corporate office portfolios.
Before you start
Gather your portable appliance tester (PAT), durable test tags, a test and tag checklist, and a pen. Verify the PAT calibration is current. Review the PAT testing checklist so you know which tests apply to each appliance class, and pull up your asset tracking system to confirm all appliances and their locations.
Step-by-step test and tag
1. Visually inspect the appliance
Before connecting the PAT tester, check the appliance for damage, cracks, burns, staining, moisture ingress or missing covers. Confirm the rating label is legible, guards and ventilation openings are in place, and the appliance suits its operating environment. If it fails the visual check, do not proceed to electrical testing.
2. Visually inspect the cord and plug
Run your hands along the full length of the power cord looking for cuts, abrasion, kinks, joins or exposed conductors. Inspect the plug for cracks, bent pins, burn marks or loose connections. Confirm the cord grip is secure at both ends and reject any cord with taped repairs or unapproved joins.
3. Connect the portable appliance tester
Switch the appliance off. Plug it into the PAT tester and, for Class I equipment, connect the earth lead clip to an exposed metal part. Select the correct test sequence for the appliance class.
4. Run the electrical tests
For Class I, run earth continuity first (pass: less than 1 ohm), then insulation resistance (pass: greater than 1 megohm). For Class II (double-insulated), skip earth continuity and run insulation resistance only. Where supported, also run a leakage current test. Record all readings.
5. Apply the test tag
If the appliance passes, attach a durable pass tag showing the test date, next test due date and tester name. If the appliance fails, apply a fail tag and remove it from service immediately.
6. Record the result in the register
Enter the result into your test and tag register: appliance description, asset ID, serial number, location, test date, tester name, individual readings, pass or fail status and next test due date. Retain records for the life of the appliance.
Test types
The table below summarises the core tests and their pass thresholds per AS/NZS 3760.
| Test | What it measures | Pass threshold | Applies to |
|---|---|---|---|
| Earth continuity | Resistance of the earth path from plug pin to exposed metal | < 1 ohm (add 0.1 ohm per metre beyond 5 m) | Class I only |
| Insulation resistance | Integrity of insulation between live conductors and earth | > 1 megohm at 500 V DC | Class I and Class II |
| Leakage current | Current leaking from live parts to earth under normal load | < 5 mA (Class I), < 1 mA (Class II) | Class I and Class II |
| Polarity | Correct wiring of active, neutral and earth conductors | Correct orientation confirmed | Extension leads, power boards, rewirable plugs |
Class I appliances have a metal chassis connected to earth (e.g. toasters, angle grinders). Class II appliances rely on double insulation and carry the square-within-a-square symbol (e.g. phone chargers, plastic-bodied drills).
Testing intervals
AS/NZS 3760 recommends testing frequencies based on the environment.
| Environment | Interval | Standard |
|---|---|---|
| Construction and demolition sites | 3 months | AS/NZS 3760 |
| Hostile environments (wet, dusty, high vibration) | 3 months | AS/NZS 3760 |
| Factories and workshops | 6 months | AS/NZS 3760 |
| Commercial kitchens and hospitality | 6 months | AS/NZS 3760 |
| Hotels, retail and commercial premises | 12 months | AS/NZS 3760 |
| Offices and low-risk environments | 5 years | AS/NZS 3760 |
These are recommendations, not law, but regulators and courts treat them as the benchmark. Deviating without a documented risk assessment is difficult to defend.
Regulatory requirements
In Australia and New Zealand, AS/NZS 3760 is the primary standard for in-service safety inspection and testing of electrical equipment. It defines who can test, what tests to perform, pass thresholds and recommended intervals. While not legislation itself, it is referenced in WHS regulations and codes of practice across every state and territory.
Under the WHS Act, a PCBU must ensure, so far as is reasonably practicable, that electrical equipment at the workplace is safe. Non-compliance can result in improvement notices, prohibition notices and prosecution. A competent person under AS/NZS 3760 is a licensed electrician or someone who has completed a recognised test and tag training course and can demonstrate competence with PAT equipment.
In the United Kingdom, PAT testing falls under the Electricity at Work Regulations 1989, with IEC 62353 for medical equipment and the IET Code of Practice for general appliances. In the United States, OSHA (29 CFR 1910 Subpart S) requires employers to ensure electrical equipment is free from recognised hazards, though there is no direct equivalent of test and tag.
Going digital with MapTrack
Paper tags fade, tear and go missing. With MapTrack, you attach a QR code label to each appliance. Anyone on site can scan the code with their phone to view the full test history, current status and next test due date without needing access to a separate system.
When a test is due, MapTrack sends automated reminders so nothing slips through the cracks. Results are recorded in your compliance register, creating a searchable, auditable digital trail. Explore the test and tag use case to see how teams are replacing clipboards with a system that keeps every appliance accounted for.
