VIRTUS Saunderton Data Centre Campus – Specialist Access Cover Solutions

R&B UK JT Ltd supplied a range of specialist D400 ductile iron access covers for the VIRTUS Saunderton Data Centre Campus in Buckinghamshire, with solutions ranging from 1000 × 1000 mm covers through to a 3000 × 3000 mm multipart system.

The project demonstrates how different access-cover arrangements can be used across a major data-centre development to accommodate varying chamber sizes, access requirements, locking requirements and large clear openings.

Project at a glance

• Project: VIRTUS Saunderton Data Centre Campus
• Location: Buckinghamshire, UK
• Sector: Data Centres / Critical Infrastructure
• Loading: D400
• Largest clear opening: 3000 × 3000 mm
• Largest multipart system: 15-part cover with two removable I-beams
• R&B solutions: Standard, locked and multipart ductile iron access covers

Project overview

R&B UK JT Ltd supplied a range of specialist ductile iron access covers for the VIRTUS Saunderton Data Centre Campus, supporting a variety of chamber sizes and access requirements across the development.

VIRTUS describes Saunderton as a campus of more than 50 acres, comprising four data centres with a combined 78MW of IT load, designed to support cloud, AI and high-performance computing infrastructure.

The scale and complexity of the development created a variety of below-ground access requirements, including several large chamber openings where a conventional single-cover arrangement would not provide the required solution.

The challenge

Large infrastructure projects rarely present one standard chamber size.

At Saunderton, the requirements ranged from conventional 1000 × 1000 mm access through to substantial openings measuring 3000 × 3000 mm.

The challenge was therefore not simply to provide D400 access covers. The solutions needed to accommodate different clear openings and different methods of access, including:

• Conventional ductile iron covers
• Locking arrangements
• Multipart cover systems
• Removable structural steel beams
• Large clear openings requiring future chamber access

For the largest chambers, maintaining practical access to the opening was an important consideration.

How R&B helped

R&B worked with the project requirements to provide a range of D400 ductile iron access solutions appropriate to the individual chamber openings.

1000 × 1000 mm

1027D Lincoln — 1000 × 1000 × 100 mm D400 cover and frame.

1500 × 1500 mm

1083DH — 1500 × 1500 × 150 mm D400 hinged four-part ductile iron cover and frame with locking.

1800 × 1800 mm

D400 six-part multipart cover and frame.

1800 × 1800 mm locked arrangement

1072D — 1800 × 1800 × 100 mm D400 four-part locked cover and frame with removable beams.

2000 × 2000 mm

D400 six-part solid-top multipart cover and frame with one removable I-beam.

3000 × 3000 mm

D400 fifteen-part solid-top multipart cover and frame with two removable I-beams.

This allowed the access solution to follow the requirements of each chamber rather than trying to make multiple locations conform to a single standard cover arrangement.

Why use a multipart access cover?

Multipart access covers provide a practical solution where the required clear opening becomes too large for a conventional single-cover arrangement.

Individual ductile iron covers divide the overall opening into more manageable sections, while structural steel beams can provide intermediate support to the cover arrangement.

Where greater access is required, these beams can be removable.

This means the individual covers can be removed first, followed by the supporting beams where necessary, providing substantially greater access to the chamber below.

R&B’s multipart systems can accommodate a wide range of opening configurations, making them particularly relevant to major infrastructure projects.

Particularly suited to data-centre infrastructure

Data centres can contain extensive below-ground infrastructure associated with:

• HV power
• Fibre
• Cooling
• Generator fuel systems
• Transformer chambers
• Draw pits
• Duct banks
• Other critical services

These systems may need to remain accessible for inspection, maintenance, equipment installation and future works throughout the operational life of the facility.

1800 × 1800 mm multipart solution

One of the specialist arrangements supplied for the project was designed around an 1800 × 1800 mm clear opening.

The system divides the opening across six D400 ductile iron covers.

A removable structural steel I-beam provides intermediate support to the multipart arrangement.

Removing the individual covers provides routine access, while removal of the structural beam allows greater access to the chamber when required.

3000 × 3000 mm multipart solution

At the largest end of the requirement was a 3000 × 3000 mm D400 multipart system.

9m² clear opening

The solution comprised:

• 3000 × 3000 mm clear opening
• D400 loading
• 15 individual solid-top covers
• 2 removable structural steel I-beams

This demonstrates one of the principal advantages of multipart design. Very large openings can be covered using individual sections while retaining a practical route to greater chamber access when maintenance, equipment installation or future works require it.

Installation and fit

Correct installation is particularly important with large multipart systems.

Frames need to be correctly levelled and squared, with the individual covers installed in their designated positions and the complete assembly checked for correct seating and rocking.

R&B multipart units are also assembled and checked for accuracy of fit before being dismantled, marked and prepared for transportation to site.

This provides the installer with an identified arrangement to follow when the multipart system is reconstructed on site.

The outcome

The VIRTUS Saunderton project demonstrates the breadth of access requirements that can exist within a single major data-centre development.

Rather than relying on one standard product, R&B was able to provide a combination of conventional large ductile iron covers, hinged covers, locked covers, multipart systems and removable-beam solutions.

The supplied solutions extended from 1000 × 1000 mm through to a 3000 × 3000 mm clear opening, allowing the access-cover arrangement to be matched to the requirements of the individual chambers.

For the largest openings, multipart construction and removable structural beams also provided a practical method of retaining access to the infrastructure below.

Working on a large or unusual chamber opening?

If your project includes a large chamber, unusual clear opening or specialist access requirement, R&B UK JT Ltd can help review the options.

Send our team the:

• Clear opening
• Required loading
• Application
• Access requirements
• Locking requirements
• Sealing requirements
• Chamber or construction drawings, where available

Our team can then review the requirement and identify an appropriate access-cover arrangement.

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