The Ardmac Internal Partition Playbook

Data Centre Construction: The Ardmac Internal Partition Playbook

Data Centre Construction: The Ardmac Internal Partition Playbook BUILDING BETTER

1.0 Data Centre Internal Partitions: Modular Whitewall

2.0 Whitewall – A closer look

2.1 Whitewall vs. Drywall : What to Consider

2.2 Whitewall vs. Drywall : Product Comparison Table

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3.0 Technical : Interface and Detailing

4.0 Service Integration & Penetration Management

5.0 Whitewall Quality Control

5.1 Whitewall Quality Control: Making The Case For Improved Site Culture

5.2 Whitewall Quality Control: Damage Control: A Quantitative Case Study Analysis

5.3 Whitewall Quality Control: Damage Control: Recommendations For Improved Outcomes

5.4 Whitewall Quality Control: Whitewall Protection

5.5 Whitewall Quality Control: Whitewall Repairs

1.0 Data Centre Internal Partitions: Modular Whitewall INTRODUCTION The phrase Modular Construction is often used to describe the assembly of three dimensional units, fabricated in an off-site manufacturing facility, before being connected on site. At a smaller but equally effective scale, the phrase Modular Construction can also be attributed to a panelised or partially pre-assembled partition system, fabricated in an off-site factory setting. Components such as flat-pack panels, parts or assemblies can be described as modular. When joined or assembled in-situ, these systems can add up to a complete a modular interior partition solution. Whitewall is a system of certified fire-rated, inter-locking, modular panels with integrated door, window and fire- stopping solutions for interior spaces. Whitewall is an economic, quick to build system, ideal for the construction of controlled environments, such as data centres. The solution offers an all-in solution that performs to a higher standard than traditional internal partition systems and generates improved construction performances as well as final results for facility owners and operators. This document identifies the primary benefits of modular internal partition systems and describes how these systems of construction can introduce improvements in the areas of safety, productivity, cost, sustainability, schedule, and quality, among others.

01. QUALITY Pre-finished product. Reduced site inspections Repairs are easy to complete. Compliant fire strategies including doors and fire stopping 02. SAFETY & REDUCED RISK Less labour & site staff reduces safety risks. Reduced working at height. 03. SPEED OF CONSTRUCTION 40% faster than traditional partition assemblies. Service penetrations are easy to implement. Enables early access for following trades.

MODULAR WHITEWALL

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Whitewall is a system of certified fire-rated, inter-locking, modular panels with integrated door, window and fire-stopping solutions for interior spaces. Whitewall is an economic, quick to build system, ideal for the construction of controlled environments, such as data centres. The product offers an all-in solution that performs to a higher standard when compared to traditional internal partition systems and generates improved construction performances as well as final results for facility owners and operators .

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04. SITE MANAGEMENT: LOGISTICS & STORAGE Internal and external storage opportunities Reduced on site handling with finished product. 05. SUSTAINABILITY Reduced management, labour, transport, site inductions

Improved compliance Recyclable materials

2.0 Whitewall - A Closer Look BUILDING BETTER

2.1 Whitewall vs. Drywall WHAT TO CONSIDER Sustainability: Modular whitewall panels are completed in a factory setting, are fully finished, and ready for installation. Therefore, less transportation is required to get materials to site when compared to drywall construction. One installation team is required to erect whitewall panels, reducing the overall site set- up, resulting in less on-site labour, inductions, toolbox talks, and overall, down-time compared to drywall. Due to reduced labour on site, modular whitewall panels reduce management, and plant and equipment. With drywall construction, multiple trades are required to finish the partitions on site. Modular whitewall panels can be ordered to the sizes required for the project, creating opportunity for zero waste at both the manufacturing facility and the site. Less material cutting reduces safety risks, improves dust control, and reduces cleaning across the site. Additionally, the materials used to make the panels are recyclable. Quality: Reduced Site Inspections: Modular whitewall panels are pre-finished meaning partitions are completed in a single installation. This reduces the risk of quality issues when compared to drywall and reduces site quality inspections and potential schedule hold points. Comparatively, drywall is installed in multiple phases, requiring site inspections as each portion of the studs, boarding, taping, jointing, and painting are completed. Safety Another key benefit of whitewall over drywall is improved safety. As modular panels are fully finished, don’t require multiple trades, and reduce overall labour, the numbers of personnel required to compete a partition in whitewall is significantly lower when compared to drywall. Fewer people on site significantly reduces the risk to safety and reduces travel time to and from the site. Additionally, whitewall reduces the risk of dust inhalation associated with cutting, sanding, and taping and jointing during drywall construction. As mentioned, only one installation team is required to erect whitewall panels, reducing the overall site set- up, resulting in less on-site labour, inductions, toolbox talks, and overall, down-time compared to drywall. Speed and Productivity: The benefits introduced through modular whitewall panels are evident when observing speed of construction. Compared to traditional drywall construction, whitewall is up to 40% faster per meter squared. This can significantly reduce overall schedule activity throughout a project and enable early access for following trades such as MEP contractors and commissioning. Where a 5-person team can

install a fully complete whitewall partition, the same area of drywall will require a 12-person team including fitters, plasterers, and painters. This is largely down to the numbers of components required to complete the partition. For whitewall, 4 components are used. Comparatively drywall requires 17 components installed over several stages. Site storage and Logistics: Whitewall can be stored internally or externally, thanks to the material makeup of the panels. The internal stone-wool core is hydrophobic and rejects moisture, while the coated metal external skins are waterproof. This means whitewall can be moved during wet weather, stored externally or internally, and without temperature restrictions. Comparatively, drywall materials must be stored internally and at a minimum of 5°C, making them less flexible from a storage and logistics perspective. Additionally, temperature control also needs to be considered for taping, jointing & painting to drywall. Typically, a min. of 10°C and relative humidity at no greater than 70-80°C is advised. This can be highly impactful on a site where internal storage space is restricted, and use of external space is necessary for deliveries and storage. Service Penetrations and Firestopping: Whitewall partition systems have undergone comprehensive fire testing with certified, established firestopping materials for service penetrations for piping, ducts, cable trays etc. Certified, tested construction details are available for a broad range of service penetration types and can be verified as a certified partition system for assurances in line with project specific fire strategies. Although service penetrations can also be formed in drywall, this usually adds significantly to the amount of labour and materials as openings are required to be engineered, cut, re-framed, or braced and then re- finished creating more complicated construction. This also increases the amount of time spent working at height for site staff installing drywall, increasing risks relating to health and safety. Also, whitewall allows tested openings larger than drywall with regards to firestopping and service integration Similar benefits exist for openings required for steel door sets. Partitions are tested and certified with selected high quality EI fire tested door products eliminating the requirement for secondary steel framing typically used in drywall assemblies.

2.2 Whitewall vs. Drywall PRODUCT COMPARISON TABLE

WHITEWALL

DRYWALL

Zero waste, single product source, reduced transport, reduced labour, reduced number of installers/trades, recycled materials 5 person team (one trade) to install fully finished whitewall Reduced site labour and working at height results in reduced safety risks. MEWP and lifting equipment required with one visit per workface Single quality inspection for a factory finished product 40% faster than drywall construction creates opportunity for early schedule activity for following trades

01. Sustainability

02. Personnel / Labour Compliance

12 person team including fitters, plasterers, painters etc.

03. Safety

MEWPs and lifting equipment involving multiple re-visits to a single workface Multiple trades responsible for site based assembly requires multiple quality inspections

04. Plant/Equipment

05. Quality

06. Speed

07. Components

08. Storage

Internal or external

Internal only

09. Transport

Single source for materials

Multiple sources of materials

Minimum 10°C for taping, jointing & painting

10. Environment

No restrictions

11. Cost

Cost effective

10% more expensive

Established, certified, fire tested service penetration and firestopping solutions. Max. opening for fire stopping 2m x 1.2m Certified up to EI240 based on panel thickness

Max. opening for fire stopping 1m²

12. Service Integration

Certified up to EI240 with more complex construction assemblies Certified fire rated door systems with secondary steel. (Required for doors weighing more than 100kg)

13. Fire Compliance

Certified fire rated door systems without secondary steel

14. Doors

Zero Waste - Materials cut to size

15. Waste

Additional Waste

3.0 Technical BUILDING BETTER

3.0 Technical INTERFACE & DETAILING

A library of established tested interface details are available for whitewall partitions. Where accessibility to both sides of a partition is limited during install, flexible detailing options such as fixing from one side can be used. Interface detailing for head tracks, fixation to profiled metal decks, deflection, beam penetrations, bulkheads, abutments to external cladding, and movement joints are also available.

4.0 Service Integration & Penetration Management BUILDING BETTER

4.0 Service Integration & Penetration Management

The management of building service penetrations within the internal partitions is a sectoral issue, creating challenges for multiple stakeholders including Ardmac, service providers and end-users. Resolving this issue through the application of a robust, well defined and controlled BIM process introduces value to projects. Where the Service Penetration Management Strategy is applied as an agreed BIM approach to managing and tracking service openings, reliable quantitative and reportable data and clarity can be provided for all stakeholders. Ardmac’s BIM lead Service Penetration Management provides a fully coordinated process from modelling through to site install. This gives our clients full visibility of project progress through use of a specific BIM Execution Plan, software and live reporting to keep all stakeholders informed on a project.

UNKNOWN TOTAL SUM Created by Anup from the Noun Project

UNDEFINED COSTS Created by Julia Holmberg from the Noun Project

FIRESTOPPING NEEDED

Created by Mint Shirt from the Noun Project

UNTRACEABLE OPE. ID’S

Click here to access the full Service Penetration Management Guidance document

5.0 Whitewall - Quality Control BUILDING BETTER

5.1 Making The Case For Improved Site Culture. PROTECT & RESPECT FINISHED WORKS

Damage to partitions, ceilings or any other scope of works caused during construction can have adverse effects on schedule, cause disruption, add cost and and increase the likelihood of remedial works. However, the extent of damage during construction varies from project to project and can be inconsistent even across similar projects in a single sector. This suggests that site specific culture is a determining factor, having a major impact on the likelihood and severity of damage. Ardmac supports and encourages a culture of respect for finished works, demonstrating our duty of care to our clients’ finished product in line with our Guiding Principle “Excellence as a Standard”. Promoting this culture can substantially lower the risk of damage to elements of work on site, reducing potential future repair costs. When undertaking any construction works, we ask that contractors promote a “Building Better” culture and aim to get it “Right First Time”.

5.2 Damage Control: A Quantitative Case Study Analysis. CAUSE AND EFFECT

The following quantitative analysis assesses the percentage of damage recorded during the architectural fit-out of data centre campuses in Western Europe. Data has been collected from six different data centre campuses across three countries, built for the same end-user. The observations in relation to damage to the internal partitions in each specific project phase have been assessed and the data recorded is represented in a diagrammatic format below. In each of the projects discussed, the project scales are similar, and products used were the same. The project example with the most damage is represented by the Project 1 diagram. In this example the GC (General Contractor) and supply chain were working collectively for the first time, on an initial building phase. As shown in the Project 1 diagram, the value of damage within the fit-out SoW (Scope of Works) was relatively high at 16% of the overall value of works. Damage, and associated remedial works to partitions accounts for 82% of all damage recorded within the SoW. Comparatively, the Project 2 diagram represents an identical building for the same end user where damage was minimised. In this case the value of damage was 1% of the overall internal fit-out final account value. Again, damage to the partitions in this example accounted for the majority of damage observed, representing 69% of the overall value of damage to the interior SoW. However, the overall cost and scale of damage relative to the overall contract value was significantly lower.

How is there such a large difference in damage accrued in Project 1 when compared to Project 2?

18%

82%

CULTURE:

16%

Rushing to meet tight project deadlines, multiple trades working along the critical path, or lack of awareness are factors that can contribute to a negative site culture and challenges in the area of quality control. These factors are often cumulative, more likely, and lead to unacceptable levels of cost and disruption as demonstrated in Project 01. Comparatively, the benefits of experience, increased awareness, lessons learned, and a lack of acceptance of damage has been observed on Project 02, leading to improved site culture and a decreased risk of damage. Recommendations for achieving improved quality standards are discussed further in the next section; Making the case for improved site culture.

SCENARIO 1 Project 01

84%

31%

69%

SCENARIO 2 Project 02

99%

5.3 Damage Control: Recommendations For Improved Outcomes. A CASE STUDY

As demonstrated, there is stark contrast between initial and subsequent project phases where lessons learned are assessed and a culture of respect is encouraged and developed between phases amongst supply chain working side by side. However, with careful planning and clear communication the project quality culture can be improved, improving outcomes for all stakeholders.

THE FOLLOWING RECOMMENDATIONS/ ACTIONS CAN BE TAKEN TO IMPROVE THE QUALITY CULTURE ON SITE.

Trained dedicated quality personnel within project delivery teams

Quality inductions

Process and technical training

Field Management Software (FMS) based management

Trade-to-Trade Hand-Over Procedures

Ongoing quality based tool-box talks

Partition protection fund

Damage/Repair fund

Damage penalty clause

Project quality audits

Quality charter agreed by all stakeholders

Weekly/monthly quality meetings

Accountability

Prevention is better than cure when it comes to risk management and damage control to partitions. It is recommended that established protection measures are put in place to ensure quality and reduce the likelihood of repairs. 5.4 Quality Control: Whitewall Protection

Protection Overview Material: OSB sheets- 1.2m X 2.4m, 50mmX25mm timber baton (50mm x 25mm) 12.5mm thick plywood kickboards of 300mm x 2.4m to prevent plant and equipment from being stored against, or driving into the panels Sheets to be fastened to bracing using countersunk screws to ensure screw head doesn’t scratch the panel. Foam gasket strips to back of boards to cushion timber against panels 2.4m centres to allow for individual sections to be removed for trade partner access Individual pieces to be “strapped” together to discourage easy removal of protection by others, but not so much as to hinder removal when required by following trades.

5.5 Quality Control: Whitewall Repairs WHAT TO CONSIDER

Where preventative measures do not succeed on a building site, effective repair methods have been introduced to minimize the effects of damage to whitewall partitions from a commercial perspective. A roller-based paint application process is circa. 1/4 of the cost of spray finishes commonly used. Additionally, this eliminates the need to segregate the area, protect the works and provide extraction, and takes 1/5 of the time usually required for a spray finish.

The Process • Complete a benchmark for each damage type e.g. scratch, dimple, dent etc. • With a marked-up drawing, identify rooms / areas that are ready for repairs. • Survey and identify repair type by colour coded sticker. • Record all damages and repairs via BIM checklist with CM / Client approval. • All repairs to be applied using rollers. • Avoid aerosol application as it tends to present greater risk to the repair team and anyone in the area due to the fumes. • Repairs to be determined by scope of damage e.g. if a small scratch, a localised repair will be completed. Repair will be a taped square section. Please refer to the photos on the next page for examples of repair works. Rolling Vs Spraying • Lower risk to repair crew and others in the area. • Less likely to require mechanical extraction. • Crisp and defined areas of repair due to precision application by roller or brush allow for seamless transitions from factory finish to repaired areas. • No risk of excess residue or over spraying onto existing services and fittings. • All applications are by hand- rollers & brushes for primer and paint and paint scraper / small trowel for panel filler. • Sanding by hand or machine with built-in vacuum for dust control. • Examples of materials to be used- “4CR 7404 high Build Primer” / “Q20-016 2K Polyester Soft Putty” / “Shield X Cladding Coat”.

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