SECTION 01 45 24

TESTING PROGRAM REQUIREMENTS

PART 1. - GENERAL
1.1. Section Includes
1.1.1. Specification Overview

1.1.1.1. Requirements for providing test support personnel and equipment to test all fabricated and
manufactured materials and equipment as required in other Sections.

1.1.1.2. Requirements for providing test support personnel and equipment to verify compliance with
specified performance requirements.

1.2. Related Sections

1.2.1. Key Sections

1.2.1.1. The Contractor shall comply with the requirements of the following related sections.

Section 01 33 00 Submittal Procedures

Section 01 36 10 Reliability, Availability and Maintainability

Section 01 36 20 Requirement Management

Section 01 43 00 Quality Assurance

Section 01 91 13 Project Integration Commissioning Requirements

Section 34 42 10 System Test Program

Section 28 60 00 Safety and System Assurance

1.3. References (Not Used)

1.3.1. General

1.3.1.1. The Contractor shall comply with the following standards.

EN 50126 Railway Applications. The Specification and Demonstration of Reliability,

Availability, Maintainability and Safety (RAMS).

EN 50128 Railway applications - Communication, signalling and processing systems

Software for railway control and protection systems

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 EN 50129 Railway applications - Communication, signalling and processing systems Safety
related electronic systems for signalling

IEC 62278 Railway Applications. The Specification and Demonstration of Reliability,

Availability, Maintainability and Safety (RAMS).

1.4. Quality
1.4.1. Specific Requirements

1.4.1.1. The Contractor shall comply with the requirements of Section 01 43 00 Quality Assurance.

1.5. Submittals
1.5.1. Specific Requirements

1.5.1.1. The Contractor shall comply with the Section 01 33 00 Submittal Requirements.

1.6. Test Responsibility

1.6.1. Specific Requirements

1.6.1.1. The Contractor shall perform all native (in-situ) field tests.

1.6.1.2. The Contractor shall perform all tests for fabricated and manufactured material that are
designed and furnished as part of the Works.

1.6.1.3. The Contractor shall perform all tests for equipment that are designed and furnished as part of
the Works.

1.6.1.4. All tests shall be witnessed by the Engineer.

1.6.1.5. The Contractor shall bear all cost for testing.

1.6.1.6. Although the Engineer

planning, scheduling, and performing the tests.

1.6.1.7. All factory and field-testing shall be conducted under the direction of the Contractor's Quality
Control (QC) group and the Test and Commissioning.

1.6.1.8. Individual subcontractor test and commissioning managers shall report directly to the

1.6.1.9. The Contractor/ Subcontractor shall furnish all test instruments and any other equipment and
material necessary to perform the tests.

1.6.1.10. Acceptance of the structures, facilities, and equipment provided under the Contract shall be
contingent upon successful compliance with inspection and test requirements.

1.6.1.11. These tests shall demonstrate the performance of the fabricated and manufactured materials
and equipment at various points of the project lifecycle.

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 1.6.1.12. The Contractor shall be fully responsible for the repair or replacement of any materials or
equipment damaged as a result of tests.

1.6.1.13. The Contractor shall apply Section 014524 for all project disciplines test requirements as
applicable.

1.6.1.14. The Contractor shall bear all associated costs resulting from Article 1.6.1.12

1.6.1.15. The Contractor shall comply with applicable International, UAE local standards and regulations.

1.6.1.16. The Contractor shall ensure testing requirements specific to individual systems are referenced
in the discipline test plans.

1.6.1.17. Each discipline shall have specific test plans with test procedures, outcome and resources
stated.

1.7. Test Documentation

1.7.1. General

1.7.1.1. Requirements for planning and performing tests, recording data, and reporting test results shall
be as specified herein.

1.7.1.2. Unless indicated otherwise, the general requirements stated herein shall apply to all testing.

1.7.1.3. The Contractor shall allow 21 Days for the review of test documentation submittals by Engineer.

1.7.1.4. The Contractor shall establish procedures required for inspecting of manufactured and
prefabricated materials either by source inspection/testing, Worksite inspection/testing, or
Certificate of Compliance.

1.7.1.5. The Contractor shall establish procedures required for accepting of manufactured and
prefabricated materials either by source inspection/testing, Worksite inspection/testing, or
Certificate of Compliance.

1.7.1.6. The Contractor shall establish procedures required for testing of manufactured and
prefabricated materials either by source inspection/testing, Worksite inspection/testing, or
Certificate of Compliance.

1.7.1.7. These procedures shall be included in the Contractor's Quality Control Plans to be submitted to
the Engineer for review and approval prior to the fabrication of the materials.

1.7.1.8. These procedures shall be included in the Contractor's Test & Commissioning Plans to be
submitted to the Engineer for review and approval prior to the fabrication of the materials.

1.7.1.9. Source Inspection/Testing is acceptance testing of manufactured and prefabricated materials

at locations other than the Worksite and shall be validated by an approved testing laboratory and
approved by the Engineer.

1.7.1.10. Special processes required in fabrication, production or installation that cannot be validated by
subsequent inspection shall be performed under controlled conditions.
Note 1 to entry: This process may include joining or special fabrication techniques for metals, welding,
bonding, heat treatment, surface treatment, corrosion control techniques, painting and special coatings.

1.7.1.11. The Contractor shall address Special Process Production Procedures and instructions per
applicable codes, standards, specification, and drawings.

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1.7.1.12. The Contractor shall address, in their Quality Plans and Test Plans, Work Plan for Special Process
Production or Installations that provides for an appropriate Work Sequence, suitable working
environment, and appropriate equipment.

1.7.1.13. The Contractor shall address, in their Quality Plans and Test Plans, appropriate Certifications for
Special Processes and Production Procedures (i.e., welding, procedures specifications, welder
qualifications procedures, welder, welding operators, and tack welder qualifications).

1.7.1.14. The Contractor shall address, in their Quality Plans and Test Plans, appropriate qualifications for
personnel performing or inspecting special processes (i.e., Certified Welding Inspection (CWI),
Non-destructive Testing Personnel Qualifications and Certifications and Special Coating
Inspector).

1.7.2. Test Plan and Schedule

1.7.2.1. The Contractor shall prepare and submit a verification and validation plan to the Engineer for
review and approval.

1.7.2.2. The Contractor shall prepare and submit test plans to the Engineer for review and approval.

1.7.2.3. The Test Plan shall list each test procedure that will be submitted by the Contractor to
demonstrate compliance with the requirements of this Contract.

1.7.2.4. This Test Plan shall include required tests needed for full system lifecycle.

1.7.2.5. This Test Plan shall include required tests needed for completion of Design.

1.7.2.6. This Test Plan shall include required tests needed for Pre-Construction.

1.7.2.7. This Test Plan shall include required tests needed for Construction testing.

1.7.2.8. This Test Plan shall include required tests needed for manufacturing and suppliers testing.

1.7.2.9. This Test Plan shall include required tests needed for Standalone testing.

1.7.2.10. This Test Plan shall include required tests needed for Integration testing.

1.7.2.11. This Test Plan shall include required tests needed for System testing.

1.7.2.12. The Contractor shall refer to Section 01 91 13 Project Integration Commissioning Requirements.

1.7.2.13. The Test Plan shall include an index describing each test with its procedure number and
objectives.

1.7.2.14. The Test Plan shall include a listing of applicable pre-requisites for each test.

1.7.2.15. The Test Plan shall include a test program personnel organization and responsibilities of each
organization level.

1.7.2.16. The Test Plan shall include test reporting methodology, including instructions for recording
pertinent test conditions, identifying, evaluating, and correcting causes of problems or failures.

1.7.2.17. The Test Plan shall include sample general test sheets and instructions for their use.

1.7.2.18. The Test Plan shall include a description of procedures for preparing and submitting test data
sheets.

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1.7.2.19. The Test Plan shall include the identification, where applicable, of the primary test agency if other
than the Contractor.

1.7.2.20. The Test Plan shall include general provisions for re-test as a result of either test failure or
modification of equipment after test.

1.7.2.21. The Test Plan shall include a description of the method used to schedule each test.

1.7.2.22. The Test Plan shall include Test Plan revision procedure and controls.

1.7.2.23. The Contractor shall prepare a Schedule of Materials Control "Frequency Tables" based on the
sampling, test methods and frequencies specified in the other Sections.

1.7.2.24. The test schedule shall be submitted to the Engineer for review and approval.

1.7.3. Test Procedures

1.7.3.1. The Contractor shall maintain a copy of all standard test methods/ procedures as specified in
the Contract documents.

1.7.3.2. The test procedures and reports shall include Test Title and ID Number.

1.7.3.3. The test procedures and reports shall include test cases statement.

1.7.3.4. The test procedures and reports shall include testing diagrams where appropriate.

1.7.3.5. The test procedures and reports shall identify the testing materials.

1.7.3.6. The test procedures and reports shall include testing equipment or element of work.

1.7.3.7. The test procedures and reports shall include names of Independent Testing Laboratory
Personnel performing the tests.

1.7.3.8. The test procedures and reports shall include applicable industry standards.

1.7.3.9. The test procedures and reports shall include list of equipment required to perform the test.

1.7.3.10. Test instruments shall be listed including manufacturer, model, type, and serial number.

1.7.3.11. The test procedures and reports shall include list of prerequisite tests.

1.7.3.12. The test procedures and reports shall include a description of the required test set up, including,
but not limited to, diagrams illustrating test equipment connections and identifying test points.

1.7.3.13. The test procedures and reports shall include step by step instructions for performing the test.

1.7.3.14. The test procedures and reports shall identify the points at which data will be recorded where
applicable.

1.7.3.15. The test procedures and reports shall include test constraints.

1.7.3.16. The test procedures and reports shall include pass/fail criteria.

1.7.3.17. The test procedures and reports shall include limits for acceptable data.

1.7.3.18. The test procedures and reports shall include an explanation of any special data reduction.

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1.7.3.19. Test data sheets shall identify the test to be performed.

1.7.3.20. Test data sheets shall be designed to include spaces to record test data.

1.7.3.21. Test data sheets shall be designed to include test date.

1.7.3.22. Test data sheets shall be designed to include signatures of individuals performing and witnessing
the tests.

1.7.3.23. Test data sheets shall be designed to include requirements under test.

1.7.3.24. Data sheets shall be arranged in tabular form where practical.

1.7.3.25. For each test procedure, general and specific data sheets shall be provided.

1.7.3.26. General or generic test data sheets shall provide a template, or general layout, for all tests in a
particular test category.
Note 1 to entry: General test data sheets can be prepared to apply in more than one test category

1.7.3.27. General data sheets shall include test identification.

1.7.3.28. General data sheets shall include date or revision number.

1.7.3.29. General data sheets shall include spaces for check-off.

1.7.3.30. General data sheets shall include testing discrepancies.

1.7.3.31. General data sheets shall include verification of the test's completion.

1.7.3.32. Where applicable, general test data sheets shall include drawing numbers.

1.7.3.33. Where applicable, general test data sheets shall include test equipment and their respective
model numbers.

1.7.3.34. Where applicable, general test data sheets shall include references to the applicable procedure
number.

1.7.3.35. Where applicable, general test data sheets shall include allowable limits for certain entries.

1.7.3.36. Where applicable, general test data sheets shall include corrective actions required.

1.7.3.37. Specific test data sheets shall contain all the information for each test category.

1.7.3.38. Specific test data sheets shall contain all each test condition pre-filled out.

1.7.3.39. Test data sheets incorporating site-specific information shall be filled out and submitted to the
Engineer 10-Days prior to conducting test.

1.7.3.40. Data entries shall be referenced to the applicable procedure.

1.7.3.41. The allowable limits for each entry shall be indicated on the data sheets.

1.7.4. Test Support Documentation

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1.7.4.1. All relevant Contractor-prepared drawings and submittals shall be available for reference during
the conduct of each test unless otherwise specified in individual Sections of the Contract
Specifications.

1.7.5. Test Equipment/Instrument Certification

1.7.5.1. Test equipment/instruments shall be calibrated certified within 180-Days prior to use.

1.7.5.2. Test equipment/instruments shall be accuracy certified within 180-Days prior to use.

1.7.5.3. Calibration certification shall be submitted with the relevant test reports.

1.7.5.4. The Contractor shall ensure all specialised systems are tested by qualified person.

1.7.6. Test Notification

1.7.6.1. The Contractor shall notify the Engineer and all participating parties 30 days before the
scheduled tests.

1.7.7. Test Witnessing

1.7.7.1. The Engineer shall reserve the right to witness any and all tests.

1.7.7.2. The Engineer shall reserve the right to appoint an independent agency as a test witness
representative or perform an independent Assurance Sampling and Testing (IAST) of the Work.

1.7.7.3. The witness(es) shall be present on a non-interfering and non-participatory basis.

1.7.7.4. All witnessing parties shall sign the test reports.

1.7.8. Test Reports

1.7.8.1. The Contractor shall maintain a copy of all test reports as specified in the Contract documents.

1.7.8.2. The test reports shall include Test Title and ID Number.

1.7.8.3. Test Reports shall be prepared and submitted to the Engineer for review and comment no later
than 10-Days after completion of the respective test.

1.7.8.4. As a minimum, the Test Report shall contain test data sheets, test commentary and a conclusion
statement.

1.7.8.5. Payment shall be withheld for all rejected test reports.

1.7.8.6. Test Reports shall include completed test data sheets prepared in accordance with Articles
1.7.3.19 - 1.7.3.25.

1.7.8.7. Completed test data sheets shall contain all site-specific information, test results, and
appropriate signatures.

1.7.8.8. The Contractor shall prepare a brief commentary on the test.

1.7.8.9. The commentary shall compare the test results and pass/fail criteria, where applicable.

1.7.8.10. In case of test failure, the commentary shall provide an analysis of the test, probable reasons for
the failure and remedial measures the Contractor intends to undertake.

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1.7.8.11. If failure is corrected during the test, the commentary shall include the corrective action taken.

1.7.8.12. The Contractor shall provide a concluding statement assessing the results of the tests (i.e.,
success or failure).

1.7.8.13. The test report shall include the measurement uncertainty.

1.7.8.14. The test report shall include specific provisions for re-test as a result of either test failure or
modification of equipment after test.

1.7.9. Rejection and Retesting

1.7.9.1. All test equipment shall be examined and inspected thoroughly immediately after the test has
been completed.

1.7.9.2. Failure of test equipment to meet the performance requirements, or damage sustained during
the test, shall be sufficient grounds for rejection of equipment.

1.7.9.3. Equipment failing to pass the test shall have deficiencies corrected by modifications, if
necessary.

1.7.9.4. Equipment failing to pass the test shall be retested without impacting the Project Schedule
unless otherwise agreed to in writing by the Engineer.

1.7.9.5. The cost of any rework of a unit of Work, or the fabrication or manufacture of a new unit of Work
including retesting and witnessing by the Engineer, shall be borne by the Contractor.

END OF SECTION 01 45 24

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