Factory Acceptance Testing (FAT) in Switchgear Quotes: What to Include

What Is a Factory Acceptance Test?

A Factory Acceptance Test (FAT) is a formal testing and inspection process conducted at the manufacturer's facility before equipment is shipped to site. For panelboards, switchboards, and MCCs, the FAT verifies that the assembly has been built to the approved drawings and specification, operates correctly, and meets the relevant Australian and IEC standards before it leaves your factory.

FATs are mandatory on most commercial and all major industrial switchgear projects. They protect both the manufacturer (by catching defects before delivery, when they're cheaper to fix) and the client (by verifying compliance before installation, when issues become much more expensive to resolve). Understanding what FAT involves — and how to scope and price it correctly — is important for every switchgear estimator.

Routine Tests vs. Type Tests

Under AS/NZS 61439 (the Australian/New Zealand standard for low-voltage switchgear assemblies), testing requirements are divided into two categories:

Routine Tests

Routine tests are conducted on every assembly manufactured. They verify the specific unit — not a representative sample. Standard routine tests for panelboards and switchboards include:

• Visual inspection: dimensional check against approved drawings, component verification, labelling, cable routing
• Wiring verification: check against approved schematic diagrams — particularly important for MCCs with complex control circuits
• Dielectric (HV) test: high-voltage test applied to busbars and insulation at typically 2.5 kV AC or 3.5 kV DC for 1 second
• Insulation resistance test: measures resistance to earth at 500V or 1000V DC
• Protective circuit continuity: verifies earth continuity throughout the assembly
• Mechanical operation test: operation of all switching devices (circuit breakers, isolators, contactors)
• Functional test: operation of control circuits, interlocks, and any integrated systems (meters, relays, BMS interfaces)

Type Tests

Type tests are conducted once on a representative assembly to demonstrate that the design meets the standard's performance requirements — not repeated on every unit. These include temperature rise tests, short-circuit withstand tests, and IP rating verification. For most manufacturers, type tests are covered by certificates held for the enclosure system and components, not by tests on individual project assemblies.

If a specification requires new type testing — either because the assembly design falls outside the manufacturer's existing type test certificates, or because the client requires project-specific type certification — this is a significant cost that must be explicitly priced and scoped. New type tests can cost $15,000–$80,000 depending on the tests required.

Client-Witnessed FAT

Many specifications require a client-witnessed FAT — meaning the client (or their representative, such as an independent inspector) attends the factory during testing. This adds several cost and coordination elements:

• Test plan and procedure preparation: the manufacturer must prepare formal test documentation, typically reviewed and approved by the client before the FAT date
• Scheduling coordination: aligning the FAT date with client availability, manufacturing completion, and delivery programme
• Witness facilities: appropriate factory space, PPE, safety documentation for client/inspector personnel
• Test report preparation: formal documentation of all test results, signed by both manufacturer and witness
• Re-test risk: if the assembly fails a test during the witnessed FAT, costs include rework time, re-test time, and potentially the client's re-attendance expenses

A simple witnessed FAT on a single switchboard might add $1,500–3,000 to the project cost (engineering time + technician time + documentation). A complex FAT on a large MCC with multiple witnesses, third-party inspector, and formal test plan approval might add $8,000–20,000 or more.

Third-Party Witness and Certification

Some high-value or safety-critical projects require the FAT to be witnessed by an accredited third-party inspection body — such as Bureau Veritas, SGS, Lloyds Register, or similar. This adds the cost of the third-party inspector's time and travel, as well as a premium for the inspection certificate itself. Third-party witnessed FATs on major switchgear packages for resources or government projects can cost $5,000–25,000 for the inspection component alone.

If the specification requires third-party certification, ensure this is explicitly priced in your quote and not buried in a generic "testing" allowance.

FAT vs. SAT: Know Your Obligations

FAT (Factory Acceptance Testing) is conducted before shipping; SAT (Site Acceptance Testing) is conducted after installation. The scope of manufacturer involvement in SAT varies considerably:

• No SAT obligation: manufacturer's scope ends at delivery, and the installing contractor handles all site testing
• SAT support: manufacturer provides technical support (typically phone/remote) during site commissioning
• Manufacturer-led SAT: manufacturer attends site and leads commissioning and testing, often specified for complex MCCs and high-voltage switchgear

If the specification mentions SAT or commissioning support, read it carefully. Manufacturer-led site commissioning can be a significant cost on large projects — particularly on remote or interstate sites where travel and accommodation add to the labour cost.

What Specifications Typically Say About FAT

FAT requirements are usually found in the "Testing and Commissioning" section of the electrical specification, or sometimes in a dedicated "Testing and Inspection Plan" (TIP) document. Key things to look for:

• Whether a witnessed FAT is required, and if so, who witnesses it (client, client representative, third-party inspector)
• What tests are required — standard AS/NZS 61439 routine tests or additional project-specific tests
• Whether a formal test plan must be prepared and approved pre-FAT
• Whether type test certificates suffice for type test verification, or new type testing is required
• The format and content requirements for test documentation and reports
• Notification period required before the FAT date

If the specification is silent on FAT details, standard routine testing under AS/NZS 61439 should still be assumed and priced — it's part of building a compliant assembly.

Common FAT Pricing Mistakes

Not Pricing the FAT at All

Some estimators exclude FAT entirely or include only a nominal allowance. If a witnessed FAT is specified, absorbing the full cost from project margin is not a viable approach on a competitive quote.

Ignoring Re-Test Risk

A FAT where a fault is found and the client or inspector must return for re-testing has a significant cost impact. While good quality control reduces this risk, a contingency for one re-test visit on complex projects is prudent.

Not Reading the Test Plan Requirements

Preparing a formal FAT test plan — with test procedures, test record templates, pass/fail criteria, and revision history — is an engineering deliverable that takes time. For a large MCC, this might be 8–20 hours of engineering documentation work. Not pricing this separately leads to cost absorption from the project.

Conclusion

FAT is a necessary and valuable part of switchgear manufacturing — it protects the client, protects the manufacturer, and creates the paper trail that demonstrates compliance. The mistake is treating it as an afterthought in the quote. Reading the specification's testing requirements carefully, understanding the difference between routine tests, witnessed FATs, and type testing, and pricing each element explicitly is the mark of a professional switchgear estimator — and is reflected in the quality and completeness of your quote.