Group Metropolitan delivers a state-of-the-art data hall testing laboratory in Knutsford

Group Metropolitan’s Northern team has successfully completed a bespoke laboratory fit-out project for a blue-chip client in Knutsford, delivering a highly complex and advanced data hall facility within a 30-week programme.

The client appointed ARUP and Group Metropolitan at BSRIA Stage 1, with both companies partnering to support the development of the detailed design. ARUP’s expertise in data centre design, in-house CFD analysis, 3D modelling and knowledge of modern technological advances such as on-chip and adiabatic cooling solutions, alongside GML’s own design capabilities and expertise in construction delivery, made this a perfect collaboration. The new installation provides advanced cooling facilities via 2nr 300kW adiabatic units and 100kW of Direct Liquid Cooling (DLC) technology. This solution enables on-chip cooling for several high-density areas, supporting the operational demands of a mixed-use high-performance data environment.

Given the age of the building, the extent of the strip-out and associated works was significant. More than 40 years of ceiling and raised access floor void services, both redundant and live, including data cabling from SERs, electrical infrastructure and fibre-optic networks, had to be carefully validated. All live services were re-routed as part of a dedicated enabling works package. This phase of the project also included the safe removal of asbestos from the floor voids, completion of structural validations, and delivery of a full Point Cloud survey to facilitate the 3D model generation, ahead of the commencement of the main construction works.

With the significant load imposed by the new plant and equipment, together with the client’s high-density rack requirements, Group Metropolitan worked in close collaboration with the structural engineering team at Arup to undertake an extensive validation of the building’s structure. This detailed assessment covered structural columns, ring beams and floor slabs from ground floor through to roof level, and played a key role in informing and shaping the final design solution.

To facilitate construction, the scope of works included the installation of a substantial scaffold and hoist system to provide access to the third floor and roof areas. Major structural upgrades were implemented to accommodate the 2nr 4-Tonne Excool units and roof-mounted ductwork array. Additional works included new polymeric roof covering, fire alarm, aspiration and dry sprinkler systems, DX cooling to the rack build rooms and office spaces, Riello 400kVA UPS systems, Cool IT CDU, PHX’s and cooling distribution systems, side stream filtration, AF switchgear panels, flexible power distribution via Anord Mardix Databar systems, Minkels cabinets and Prism hot aisle containment systems. A considerable extent of fabric work was also required to create the fire rated walls and glazing system that formed the viewing gallery within the facility.

System commissioning was embedded from the early stages of construction, with Factory Acceptance Testing (FAT) scheduled for all major plant and led by Group Metropolitan’s in-house commissioning management team, supported by Group Metropolitan’s dedicated Building Management Systems (BMS) department. The entire solution was commissioned in accordance with ASHRAE standards, Levels 0 through to 6. Site Acceptance Testing (SAT), witnessing activities and end-user training were attended by a wide range of stakeholders, including OEMs, ARUP, the client, Group Metropolitan’s project delivery teams, the end user and the site’s incumbent maintenance provider. Level 4 functional performance testing incorporated the installation of rack emulators for the adiabatic cooling requirements, while temporary boilers provided representative thermal loads for the commissioning of the on-chip cooling systems.

Despite the complexity and sensitivity of the works, the project was delivered without service interruption, incident, or complaint. Notably, all activities were completed directly above a live, mission critical Command Centre and an occupied floorplate, highlighting the team’s diligent planning and technical expertise in operational continuity.

Adam Williams, Northern Divisional Director, Group Metropolitan said: “This project is a strong example of our Northern team’s capability to deliver technically complex, high-value environments within live and operational settings. The collaboration across our internal teams and with ARUP was key to achieving a successful outcome, and we’re extremely proud of the results delivered for our client.”

For more information visit https://groupmetropolitan.com/, email enquiries@groupmetropolitan.com or call 0800 0276 501.

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