Design ID provided comprehensive civil and structural engineering services for the BER 22 project, a 16 MW IT data centre in Mittenwalde, Germany. The project involved designing drainage systems, Sustainable Drainage Systems (SuDS), external levels, and coordinating below-ground services.
Design ID conducted site visits to monitor progress, ensuring compliance and addressing potential issues. They resolved drainage conflicts, optimised the drainage network, and redesigned site entrances to improve traffic flow. Additionally, performing structural checks and calculations for critical elements, ensuring safety and integrity. The proactive approach reduced risks, costs, and project delays, showcasing expertise in delivering innovative and reliable engineering solutions for high-demand infrastructure projects.
Spanning over 5 hectares, the BER 2 campus features a low-rise design with a data centre building that has a gross internal floor area of around 18,000 m², along with associated yard areas. The campus will ultimately house two high-tech data centres, providing a combined IT load capacity of 32 MW. BER 22 is the final data centre to be constructed within this campus.
Design ID was responsible for delivering a comprehensive range of civil engineering design services, ensuring seamless project integration and site functionality. The scope of work included the design of drainage systems and Sustainable Drainage Systems (SuDS), detailed external levels, and thorough clash detection and coordination of all below ground services. Additionally, Design ID provided cut and fill earthworks design, swept path analysis of construction and permanent traffic, and developed detailed road markings and signage designs. Pavement calculations and alterations to the site entrance were also key deliverables, showcasing a holistic approach to the site design.
Design ID conducted multiple site visits to monitor construction progress, ensuring compliance with design specifications and proactively identify potential issues before they impacted the project timeline. Detailed inspection reports documented any defects, ensured adherence to regulations, and promoted a safe working environment. This approach enabled Design ID to refine designs as needed, avoiding delays and reducing project costs.
In the early design stages, contradictory drainage information was swiftly identified and resolved to maintain project momentum. To resolve this, linear drains and gullies were strategically added to reduce ponding risks, particularly following a redesign of the levels. The surface water treatment structures were reviewed against DWA-M 153 and verified by the local ACO representative to ensure that the structures met project specifications. To achieve a seamless integration of surface water, foul water, and condensation networks with structural elements, street furniture, and underground services Design ID utilised advanced BIM models for 3D clash detection which enabled precise coordination and minimised construction conflicts.
Design ID undertook a value engineering exercise to the drainage network for the BER 22 site. To aid with this exercise Design ID requested that additional infiltration and groundwater testing were carried out to validate results against early-stage design data. By incorporating local precipitation data and tests results into calculations, Design ID optimised the drainage calculations and reduced the size of a soakaway tank by 50% while ensuring the drainage network maintained sufficient capacity. The reduction in tank size also reduced the extent of temporary works required to create safe excavations for installation of the tank structure. This demonstrates Design ID’s commitment to cost-effective and dependable engineering solutions.
Initial designs proposed a shared entrance and exit gate for BER 22 and the adjacent data centre. Recognising potential traffic disruptions, Design ID conducted a thorough due diligence review and proposed a solution involving separate entrances and exits for the two sites. This required updates to the existing access point for the adjacent data centre and the design of a new, dedicated entrance for BER 22, with all underground services coordinated to serve the revised gate configuration.
Further site investigations revealed that the proposed BER 22 entrance was insufficient for anticipated traffic, particularly for heavy goods vehicles (HGVs). To address this, Design ID conducted a Swept Path Analysis, evaluating both construction-phase and permanent traffic flows. Solutions included reducing the central island’s length to facilitate HGV movements, ensuring minimum clear widths for entrance gates, and coordinating intercom installations to avoid conflicts with existing underground services. These measures enhanced traffic flow and optimised site functionality.
Design ID were entrusted with assisting with remedial measures to an adjacent data centre. The first remedial measure to complete was a drainage verification calculation to ensure compliance with Client requirements and verify drainage works completed. The second remedial measure involved completing an earthworks design for the area behind the HV substation.
Following comprehensive site due diligence, Design ID noted the initial proposed level design did not account for existing boundary levels behind the substation area in the adjacent data centre site, as such the constructed proposed levels around the HV substation did not align with the existing levels. Design ID performed a detailed cut and fill analysis of the substation area to allow for 1300m3 of site won material to be used to ensure the proposed levels tied into the existing boundary levels. This achieved a cut and fill balance across the site saving project costs. The earthworks design also highlighted issues that had not been previously identified such as insufficient cover to the HV cables and the design rectified these issues as the levels were increased to provide sufficient cover. Due diligence checks by Design ID prior to commencing the earthworks design ensured loading limits above the attenuation tank were adhered to. The earthworks design further highlights Design ID’s sustainable approach to design ensuring that materials are reused where possible helping to reduce project costs.
Design ID was engaged to conduct comprehensive checks and calculations for critical structural elements, including the transformer platform, fuel pipe bridge, chiller platform, and trash compactor slab. These calculations encompassed key structural components such as transformer platform loading arrangements, connection forces, and stability assessments. For the fuel pipe bridge and roof platform, Design ID meticulously analysed the steel frame configurations and connection details to ensure structural integrity under operational loads. Additionally, for the trash compactor slab, the team designed a reinforced base slab capable of withstanding dynamic and static loads while maintaining durability and longevity.
This assertive and methodical approach not only ensured that each structural element was fit-for-purpose but also provided the client with detailed insights into the engineering performance and safety of the overall design. By addressing potential challenges early in the process, Design ID contributed to reducing risks, avoiding costly design revisions during construction, and optimising the project timeline. This proactive and detail-oriented methodology underscores Design ID's commitment to delivering robust and reliable solutions that align with the project's operational and structural demands, ensuring its long-term success.
The chiller platform spans over 4,100 m2 and was meticulously designed and fabricated to accommodate the equipment while maintaining the structural integrity of the building. Another challenge faced was ensuring that the 75-meter stretch fuel bridge was correctly aligned and strengthened. This was achieved through advanced steelwork engineering. This project is an example of Design ID’s expertise in steel structure design for high-demand infrastructure projects, such as data centres.
The BER 22 project underscores Design ID’s expertise in the technology and data centre sector. Through a diligent, cost-effective, and time-efficient approach, Design ID delivered innovative solutions and strengthened its reputation for excellence. This project exemplifies the company's ability to address complex challenges, build enduring client relationships, and deliver success in every aspect of project execution.
