A test pack or final test pack is a comprehensive document used during the construction and commissioning phase of a project [commercial real estate / data centres etc], serving as a formal documented record that ensures all systems are tested, verified, and ready for operation before handover to the owner or client.
Using a pack serves three purposes:
- Usually complies with the overall project commissioning process.
- Ensures that all necessary documentation related to a specific test is consolidated for reference throughout the testing, helping the team with the information that is required and needs to be referred to.
- Allows quick and easy access / understanding of what and how the works were completed if ever needed in the future by the building operator.
⬛ 5 Key Take Aways
- Test packs are essential documents that provide a structured approach and documented evidence to equipment and systems verification, serving as both a testing guide and future reference document.
- A well-organized test pack follows a standardized 10-section format, from front cover to photo records, ensuring consistent documentation across all systems and equipment.
- A 13-step process for managing test packs, from creation to final incorporation in O&M manuals, requires clear coordination between the General Contractor (GC) and Commissioning Agent (CxA).
- Early creation and proper organization of test packs, including temporary and final filing systems, is crucial for efficient management and successful handover to the client and building operator.
- Test packs are very different from turnover documents – while test packs focus on detailed testing verification, turnover documents encompass broader operational information including manuals, warranties, and maintenance details.
🟩 Benefits if Using a Test Pack
- ✅ Ensures thorough documentation is created and maintained of all tests conducted on the building plant, equipment and systems for reference during the testing and later during the building operations.
- ✅ Provides a clear record for compliance with project specifications and any regulatory requirements.
- ✅ If there are any queries or reviews required later of the testing completed, the document allows for quick and easy understanding of how the testing was completed and what information was used, Especially useful as the person reviewing may not have any prior knowledge of the project.
Using a pack serves three purposes:
- ✅ Usually complies with the overall project commissioning process.
- ✅ Ensures that all necessary documentation related to a specific test is consolidated for reference throughout the testing, helping the team with the information that is required and needs to be referred to.
- ✅ Allows quick and easy access / understanding of what and how the works were completed if ever needed in the future by the building operator.
🟩 Here is our video on ‘Test Packs’
The below guide explains what a Test Pack is and how it is formatted. For the overall process continue to read this article.
🟩 What is the Format of a Final / Test Pack?
To ensure that all relevant documents, drawings, schedules are available at any specific test, a pack will typically include the following:
🔗 to understand the requirements for ‘document approvals / status please refer to our article STATUS A, B, C & D | What do they mean…
| Title | Other Info | |
|---|---|---|
| Front Cover | Why: this will be used to display information related to the testing, logos and allow control and visual representation of the overall progress / status of the ‘pack’. Include: logos, internal approval section, test number, project name, test type / works, checklist for each section with yes / no / na, space for sign off and approval. Cx Responsibility: oversee and manage the information ensuring is up to date and represents the status of the overall document. |
|
| Section 1 | Material Submission | Why:to ensure that the systems, materials, plant and equipment installed aligns with the expectation of the Designer and Client. Include: copy of submission, any comments and status page as signed / chopped by the responsible party [usually the Designer]. Cx Responsibility: to review before / during the testing, ensuring that comments have been addressed / closed and any outstanding do not impact the overall testing being conducted, materials, equipment and plant installed are aligned with the document. 🚀Should also be used for reference when approving the test script, procedure and method statement. |
| Section 2 | Factory Testing Report and Status | Why: to ensure that any equipment that has been factory tested has an approved report and that there are no comments outstanding that could affect the overall site works. Or if there are any tests from the factory that need to be completed onsite. Include: factory test report and comments / observations / punch list items. Cx Responsibility: review the document to ensure the report is approved and all comments are closed out or will not affect the testing being conducted. 🚀Also, ensure that any tests from the factory document moved to the site testing are completed and documented. |
| Section 3 | Material Onsite / Delivery Inspection | Why: to ensure that any equipment that has been delivered and is to be installed is inline with expectations and that the project process has been followed. Include: material onsite / delivery inspection checklist that is approved and signed by the project clerk of works including any comments / observations / punch list items. Cx Responsibility: to ensure that the document is include in the test pack prior to testing taking place and that there are no outstanding comments / observations / punch list items that could affect the testing. |
| Section 4 | Installation Inspection | Why: to ensure that any equipment that has been installed inline with expectations, drawings and project requirements - following the project process. Include: installation checklist that is approved and signed by the project clerk of works including any comments / observations / punch list items. Cx Responsibility: to ensure that the document is include in the test pack prior to testing taking place and that there are no outstanding comments / observations / punch list items that could affect the testing. |
| Section 5 | Approved Test Script / Procedure | Why: to ensure that there is a testing script related to the works, approved by the Cx Consultant, that will be used and completed during the testing to stipulate what is required. Include: approved testing script / method statement that is approved by the Cx Consultant including outstanding comments / observations / punch list items for reference. Cx Responsibility: to ensure that the document is include in the test pack prior to testing taking place and used through out the works, completing and adding information to the required sections where required. |
| Section 6 | Marked Up Record / As Built Drawings | Why: to ensure that the construction drawings related to the works are now approved ‘as built / record drawings’ by the designer / clerk of works. Include: approved testing script / method statement that is approved by the Cx Consultant including outstanding comments / observations for reference. Cx Responsibility: to ensure that the document is include in the test pack prior to testing taking place and used through out the works, completing and adding information to the required sections where required. 🚀Covering layouts, schematics, sequence of operations, control logics, wiring diagrams etc. |
| Section 7 | Calibration Certificates | Why: Calibration certificates are required to prove that, prior to testing taking place, all equipment / instruments being used are accurate and meet the required measurement standards. Include: Physical certificate that is ‘current and in date’ [usually within a year of each calibration] for each instrument being used. Cx Responsibility: Prior to testing starting, review all instruments and ensure the following 1. current Calibration Certificate, 2. Calibration Sticker on instrument, 3. Serial number of instrument matches equipment, certificate and sticker. |
| Section 8 | Other Information: | Why: Sometimes, depending on the works being completed ‘other information’ will be obtained or required for the test / final test pack. This could cover items such as specialist reports and certificates. Include: Items such as welding inspection reports, water quality reports, calibration of sensors, BMS point list, Arc flash studies, CFD studies, discrimination studies etc. Cx Responsibility: To review and ensure documentation is included. Some will be required for the testing and some, such as reports, will be required after the testing, prior to approving the testing pack. |
| Section 9 | Test Record | Why:Usually a test script / procedure the ‘test record’ will form a single section of a larger document. To ensure that the information is clear used and completed at the testing, we would print the dedicated testing section of the approved script / procedure and insert / manage it here. Include: dedicated testing section from the approved script / procedure and list of comments / observations / punch list items. Cx Responsibility: to review and ensure it is inline with current approved document, is completed clearly through the testing and includes any comments / observations / punch list items. |
| Section 10 | Photo Records | Why:depending on the works, sometimes there will be a requirement to take and document the testing with photographs. Include: any photos that have been taken, ensuring that they are clear and labelled. Cx Responsibility: ensure, where needed, they are included in the test pack. |
Overall, the format should follow a structured layout with clear sections, ensuring clarity and ease of access / future reference.
🟩 Is a Test Pack the Same as a Turnover Document?
No, a test pack is not the same as a turnover document.
While both are important in the overall project delivery, the Test Pack focuses on documenting the detailed testing and verification of plant, equipment and systems performance, whilst a Turnover Document primarily serves as a formal handover record that includes operational manuals, final test packs, warranties, and maintenance information for the owner or client.
🟩 When to Create the Test Packs
Our view is that the best time to create them would be as early as possible.
For us we would usually ensure the project starts to build them once the plant, equipment / systems, test scripts and method statement trackers have been taken off and verified; as these will be used for reference and the basis for producing them.
🟩 13-Step Test Pack Process
As can see below the process that can be implemented on a project to create, manage and approve the testing packs is quite simple and straight forward.
🟧 Step 1: Equipment / System Take Off
Once the equipment / system take off’s / script take offs, creating a full detailed schedule of assets and documents for the project, has been completed, the preparation for the test packs can be started.
These lists can be used as a reference to understand the quantity of equipment and type of tests needed.
⬜ Responsibility:
⚠️Depending on the overall responsibilities in the commissioning plan, there could be different responsibilities, but as noted below.
👷 General Contractor [GC]: the General Contractor would usually be responsible for their own equipment and system take offs.
🧑💼Commissioning Agent [CxA]: The CxA will usually conduct their own take off at the is stage, to provide an overview of the requirements and also cross reference with the General Contractor schedules.
🟧 Step 2: Agree Test Pack format
To ensure that the whole project is on the same page, the test pack format should be agreed between the different team members.
🚀 This should be quite simple and quick to do as should already be detailed within the project commissioning plan, there forming part of the overall contract documents.
⬜Responsibility:
👷 General Contractor [GC]: the General Contractor would create an ‘example’ Test Pack and issue to the CxA for approval.
🧑💼Commissioning Agent [CxA]: The CxA will, coordinate with the client and facilities teams to obtain their comments / feed back before making their own comments / approving the document.
Usually as per the overall project commissioning plan.
🟧 Step 3: Agree Test Pack Numbering
Test pack numbering is a critical component in the process and especially later when managing and tracking the packs, there could be hundreds.
🚀 This should be quite simple and quick to do as should already be detailed within the project commissioning plan, there forming part of the overall contract documents.
⬜ Responsibility:
👷 General Contractor [GC]: the General Contractor would create an ‘example’ Test Pack number format and issue to the CxA for approval.
🧑💼Commissioning Agent [CxA]: The CxA will, coordinate with the client and facilities teams to obtain their comments / feed back before making their own comments / approving the format.
Usually as per the overall project commissioning plan.
🟧 Step 4: Create Test Pack Register / Schedule
Using all the information created and approved in the previous steps, create the project commissioning test pack register / tracker / schedule, usually in Excel.
This register should detail all information such as:
- ID Number based upon approved commissioning numbering system
- Overall status of pack
- Date for latest update
- Area to capture notes for each pack
- Responsible Party
- Description of what the pack relates to
- Plant / Equipment / System ID and Location
- Type of System [HVAC, EE, PD, FS etc]
- Column’s for tracking each section of the pack [Section 1-10]
Here is our Final Test Pack Format Template for your Download and use. The pack includes the following:
- Final Test Pack Template
- Final Test Pack Creation and Filing Process
- Final Test Pack Progress Simple Tracker
⬜Responsibility:
👷 General Contractor [GC]: the General Contractor would create their own test pack register and schedule to use for their own records and tracking.
🧑💼Commissioning Agent [CxA]: at the same time the CxA will create their test pack register and schedule to use for their own records and tracking.
🟧 Step 5: Build / Create Test Packs
Once the test pack register has been completed, it’s now time to create each individual test pack physically.
This can be done in a couple of ways:
- Create each pack manually – depending on the quantity, can take a lot of time and effort.
- Use simple automation, that is built into Microsoft Word and Excel, if set up correctly can be very fast.
⬜Responsibility:
👷 General Contractor [GC]: the General Contractor would create the test packs for the project based upon the agreed format.
🧑💼Commissioning Agent [CxA]: the CxA will oversee that the packs are created and in the correct format.
🟧 Step 6: Create [Temporary] Filing
We usually use a temporary filing system onsite to differentiate the incomplete test packs from the approved and signed off ones.
Its quite simple – we use large plastic boxes, depending on the quantity of documents, labelled as their system type [mechanical, electrical, controls, fire & life safety, bms etc] and for ‘not started’, ‘in process’, ‘complete ready for review and signing’.
Each pack will then be placed in it own individual document wallet and placed into the ‘not started’ box, before moving through the process, where will be ‘complete and signed off’ then put in the permanent folders ready for the handover to client and facilities.
⬜Responsibility:
👷 General Contractor [GC]: the General Contractor would create all filing systems for the project packs.
🧑💼Commissioning Agent [CxA]: the CxA will oversee that the creation of the filing, ensuring it matches the overall expectations.
🟧 Step 7: Print and File Test Packs
Once the test packs have been created electronically, with the temporary filing available, they can all be printed, placed into a wallet and the relevant temporary box.
⬜Responsibility:
👷 General Contractor [GC]: the General Contractor will print and consolidate all packs.
🧑💼Commissioning Agent [CxA]: the CxA will oversee and ensure that they are all printed and ready in time for the testing and commissioning activities.
🟧 Step 8: Create [Final] Hard Copy Folders & Filing System
Upon completion of the project there will usually be a requirement to provide a set of hard copy documents covering all the testing and commissioning works as part of the overall project O&M Manual.
To make this as painless as possible, setting up an onsite [final] folder and filing system in the early stages to allow consolidating and storing this documentation will save a lot of time, headaches and resources.
The following provides a high level process of the steps to do this:
- How many folders: Decide on how many A4 folders and dividers are required by evaluating the ‘test pack register’ that was created earlier in the process. You will be focusing on the identification numbers such as ee-018-lv switch board, ee-022-lv cables, fs-012-gaseous system, mvac-042-chilled water pumps. You can find there might be up to 100.
- Add additional folders: depending on the quantity of ‘test packs’ you have based on the quantity of system and equipment, you may need to purchase folders and dividers in addition to the ones counted from the ‘test pack register’.
- Use / purchase A4 lever arch folders and dividers: based upon the above quantity of folders and dividers [1-20 / a-z] calculated, purchase.
- Labelling of Folders: Once the purchased folders have arrived, label each one by creating a spine label for each. The label should include the identification number, description and folder number
- Insert relevant dividers into each lever arch folder.
⚠️ Do not put the packs into the folders at this point, this comes later.
⬜Responsibility:
👷 General Contractor [GC]: the General Contractor would create all filing systems for the project packs.
🧑💼Commissioning Agent [CxA]: the CxA will oversee that the creation of the filing, ensuring it matches the overall expectations.
🟧 Step 9: Create Site Shelving
There will need to be a shelving system built onsite to store and manage the folders. Usually would be part of the contractor scope to build and create based on the specifications given by the commissioning consultant / contractor commissioning engineers.
Ensure there is additional space for expansion.
⬜ Responsibility:
👷 General Contractor [GC]: the General Contractor would build all filing systems for the storage and management of the project packs.
🧑💼Commissioning Agent [CxA]: the CxA will oversee that the creation of the storage systems to ensure that they need the project expectations.
🟧 Step 10: Manage Overall Process
Managing the overall process is pretty simple and straight forward, the contractor as noted above, creates the packs / filing systems and manages them throughout the project, until they are complete and ready for issue to the commissioning consultant for review and sign off.
At the completion of the project – the [final] folders will then be taken by the contractor and incorporated into the O&M.
Progress and completion of the packs will be completed by the contractor and CxA via monitoring and updating the test pack register.
⬜ Responsibility:
👷 General Contractor [GC]: the General Contractor would be responsible for the overall process, ensuring that they and their contractors / suppliers are delivering the testing and commissioning documentation inline with project expectations.
🧑💼Commissioning Agent [CxA]: the CxA will oversee that the process is being delivered by the General Contractor and raise any concerns where required.
🟧 Step 11: Ensure Test Packs are at Testing, Used and Returned
At each morning daily coordination meeting where the planned testing is discussed and understood the relevant test pack should be retrieved from the [temporary] filing / box by the contractor and given to the engineers that will be responsible for completing the works.
The packs at this stage, should be fully complete and used at the testing to record the activities and provide proof of what was done, including any observations.
If the completed testing pack is not available then testing should not commence.
When the onsite activities have been completed the test pack should be placed in the ‘complete ready for review and signing’ temporary box for the collection and review by the CxA. If there are still works to complete under this test pack then it should be placed in the ‘In Process’ temporary box for retrieval later.
⬜ Responsibility:
👷 General Contractor [GC]: the General Contractor would be responsible for managing the test pack availability, ensuring that they and their contractors / suppliers are using and keeping them updated.
🧑💼Commissioning Agent [CxA]: the CxA will oversee and monitor that they are being used at the testing process is being delivered by the General Contractor and raise any concerns where required.
🟧 Step 12: Review & Approve for O&M / Final Records
All completed test packs should be provided by the General Contractor to the Commissioning Consultant for review prior to them being inserted into the final A4 lever arch filing system.
Each test pack should include all completed sections as agreed between the commissioning consultant and contractor.
⬜ Responsibility:
👷 General Contractor [GC]: the General Contractor would be responsible for issuing all the completed testing packs to the CxA for their review and approval, prior to incorporating them within the final filing system and O&M.
🧑💼Commissioning Agent [CxA]: the CxA will be responsible for the review and final approval of all final testing packs [subject to the contract] oversee and monitor that they are being used at the testing process is being delivered by the General Contractor and raise any concerns where required.
🟧 Step 13: Incorporate in O&M / Final Records
Once all packs have been approved for the project and filed, they will all then form part of the overall O&M Manual and issued to the end user / facilities team / client by the contractor.
⬜Responsibility:
👷 General Contractor [GC]: the General Contractor, once the pack has been reviewed and approved, will file each one into the relevant file and section of the onsite filing system, prior to then issuing as part of the O&M.
🧑💼Commissioning Agent [CxA]: the CxA will oversee and monitor that they are being filed correctly and that all are filed prior to issuing to the project for the O&M.
🟩 How Long Do Project Test Packs Take to Create
Individually they can be quite quick to produce, especially if use some software such as Microsoft Word or Excel, but the time required to create all packs can vary based on:
- Size of project and how many are required.
- The complexity of the systems being tested.
- The amount of documentation generated during testing.
Typically, it can take from a few days to several weeks to compile all necessary documents, especially if multiple systems are involved.
⬛ Related Articles
ASHRAE | STANDARD 202 – Is it worth $100…
RFP / RFQ TENDERING PROCESS | How to Complete in 20 Steps
TENDER INTERVIEWS | Simple Guide
PUNCH LIST | Explained with Template
ASHRAE | Commissioning Stakeholders Guide – Brilliant, Love it…
COMMISSIONING MEETINGS | Explanation and downloadable agenda
