Test & Tag for Warehouses and Logistics: What Proper Test & Tag Looks Like

Warehouses and distribution centres present higher electrical risk than office environments. Equipment is spread across large areas, moved frequently, and exposed to mechanical stress from forklifts, pallet jacks, and heavy loads.

Battery chargers run continuously. Extension leads and powerboards are deployed temporarily to support loading, packing, or maintenance operations. Equipment gets knocked, dragged, or subjected to dust, moisture, and temperature variation.

Fault rates are higher. Testing intervals need to reflect actual usage and environmental conditions, not generic assumptions.

Proper Test & Tag under AS/NZS 3760 requires equipment to be de-energised and disconnected before testing. A visual inspection is performed first — checking plugs, cords, strain relief, and appliance casings for damage or deterioration.

Electrical testing follows, using calibrated PAT testers. This includes earth continuity tests for Class I items, insulation resistance tests, and leakage current measurement where applicable. Results are measured and recorded, not estimated.

Items that fail are locked out or removed from service immediately. Pass tags display the test date, next test due, and tester details. Every test is logged digitally with asset identifiers and measured values.

Visual-only tagging without electrical testing is not compliant. Neither is testing equipment while still plugged in or energised.

Testing in a busy warehouse requires coordination. The goal is to minimise disruption while ensuring all equipment is tested properly.

Liberty schedules testing to avoid peak dispatch periods. Testing often starts before 8:30am, when fewer staff are on-site and operational activity is lower. For larger sites, testing is staged by zone or building, allowing parts of the facility to continue operating while testing proceeds elsewhere.

Temporary equipment like extension leads and portable tools can be grouped and tested during scheduled maintenance windows or after-hours, if preferred. The key is planning the sequence with operations managers so critical functions remain uninterrupted.

Liberty's on-site process follows a systematic method designed to ensure nothing is missed and all testing is defensible.

Each zone or room is labelled. A room-by-room approach ensures all equipment is accounted for. Each item is unplugged, visually inspected, and electrically tested according to its appliance class, Class I, Class II, leads, RCDs, or powerboards.

Testing is performed with calibrated PAT testers that record measured values for earth resistance, insulation resistance, and leakage current. Pass or fail tags are applied on-site. Unsafe items are locked out or physically removed from the workplace.

Hazards identified during testing, for example, damaged cords, broken strain relief, or missing earth pins, are documented and reported. Results are captured digitally in real time, including defect notes and photos where relevant.

This process creates a complete record of what was tested, when, and with what result—suitable for audits, insurance reviews, and WHS inspections.

Documentation is what makes Test & Tag defensible. A tag on an appliance shows compliance at a glance. The supporting records show the testing data.

Liberty provides a complete asset register showing every item tested, including make/model, location, and unique identifier where applicable. Test histories track results over time, highlighting trends or recurring faults.

Measured results are recorded for each test; earth resistance, insulation resistance, and leakage current values where applicable. Defect notes document any issues found and actions taken.

This creates an audit trail that satisfies SafeWork inspectors, insurer requirements, and formal WHS or ISO management systems. It shows that testing was done properly, not just performed as a checkbox exercise.

Test & Tag is not a standalone activity. It integrates with WHS systems and practices; maintenance schedules, risk registers, and preventive control measures.

Defect data identifies patterns, such as frequently damaged leads in loading zones or recurring faults in specific equipment types. This information feeds into hazard management and procurement decisions.

RCD testing, emergency lighting checks, and fire equipment inspections can be coordinated with Test & Tag cycles, reducing administrative burden and ensuring all compliance activities are synchronised.

A functional WHS system treats electrical compliance as routine operational maintenance, not a periodic add-on. Test & Tag is one element of that system, proactive, documented, and integrated.

Some businesses assume visual tagging without electrical testing is sufficient. It is not. AS/NZS 3760 requires both visual inspection and electrical testing.

Others believe equipment can be tested while still energised or plugged in. This is incorrect and unsafe. Proper testing requires de-energised equipment.

Low-risk areas such as offices or staff rooms are sometimes overlooked. All portable electrical equipment in the workplace must be tested, regardless of perceived risk.

Finally, Test & Tag is not a once-off task. It is cyclical. Equipment must be retested at intervals appropriate to its use and environment, as determined by the PCBU or competent person conducting the risk assessment.

Warehouses and logistics centres require staged, systematic testing with documented evidence. Competent Test & Tag protects people, supports operations, and integrates with a functional WHS system. When testing is done properly, it becomes routine risk management — not an afterthought.

Learn more about our approach to electrical compliance done properly.