April 2, 2018

Merck K 22 data center rendering
Photo courtesy of Gensler

Energy efficiency is a challenge for many mission critical, energy-intensive data centers, but top pharmaceutical manufacturer Merck and Company’s new Tier III data center facility in Kenilworth, New Jersey has achieved just that. The facility recently received coveted ENERGY STAR certification from the U.S. Environmental Protection Agency (EPA).

Delivered by the integrated design-build team of Merck, DPR, Gensler and CCG, the data center has been commissioned to satisfy Merck’s stringent design criteria and performance-based certification process to earn ENERGY STAR designation. This is the first ENERGY STAR certified data center for Merck.

Designed and built in just eight months, the integrated team delivered the facility a full month ahead of schedule. The project scope included conversion of a one-story, steel-framed manufacturing building into a new state-of-the-art energy efficient data center. The 42,000-sq.-ft. facility includes two data halls and administrative support space. Major components include a chilled water cooling system utilizing prefabricated chiller plants and computer room air handler units in each data hall, and an electrical system comprising two power train systems in an N+1 redundancy configuration. Each of those systems consists of switchgear with dedicated standby generators and four uninterruptable power supply modules.

DPR’s Brett Korn pointed out that the data center’s ENERGY STAR designation translates into real operational savings for Merck, estimated at around 5 percent of the facility’s typical operating budget. Achieving ENERGY STAR status also highlights the responsibility global market leaders like Merck place on reducing carbon footprint and lowering operating costs through environmentally responsible development.

Korn added, “ENERGY STAR certification shows that a company is looking to reduce costs and to operate the facility in the most efficient way possible, even while focused on creating highly reliable infrastructure. In data centers, you’re putting in redundant equipment which can impact energy efficiency. By installing highly energy efficient data processing equipment that allows the facility to operate at higher temperatures, Merck achieved maximum efficiencies and lowered its operating costs. Monitoring and documenting the equipment’s performance for a full year afterwards was key and takes time and patience.”

Photo courtesy of ENERGY STAR

Engaging a design-build team with the level of technical construction expertise and data center experience that Merck, DPR, CCG and Gensler possess was also crucial to the project’s success. The project team focused on achieving energy efficiency goals from the onset. The team meticulously tracked and adhered to performance milestones to help the facility achieve both ENERGY STAR status and LEED Silver certification from the US Green Building Council.

At the end of the day, Korn pointed out that multiple factors contributed to driving the project forward to successful completion and to helping it attain ENERGY STAR status, including:

  • a knowledgeable motivated client committed to achieving specific energy-related savings goals and willing to take a different path in the design, construction, operation and monitoring of their data center facility;
  • a highly experienced project team that pursued targeted energy-related goals from day one, understanding if any system deviated from pre-established guidelines, it could not negatively impact the energy consumption of the facility;
  • the appointment of specific individuals on the project team responsible for actively tracking and monitoring the design criteria, systems, and performance indicators to ensure milestones were met; and
  • the team’s willingness to innovate by employing lean construction and extensive levels of prefabrication (estimated at 25 percent of the facility).

This data center project has allowed Merck to meet its business objectives in the region while building a solid foundation for future work and forging a lasting bond between DPR and Merck. “Merck’s mission is ‘Inventing for Life’ by improving the quality of life for the world,” shared Michael J. Abbatiello, who oversaw creation of Merck’s design criteria document which outlines the required technical specifications used for bidding, detail designing, commissioning and operating the facility. “Not only do energy efficient facilities reduce operating costs, but they also represent the environmental benefits that align with our mission.”

The Merck project was DPR’s first major new customer for its New Jersey office, which initially opened in 2008 and has doubled in size, serving customers throughout the state.

ENERGY STAR certification requires that energy consumption data be continuously tracked and professionally verified using an online reporting tool via EPA, hitting specific benchmarks. Recertification is required annually. For more specifics, go to www.energystar.gov/ENERGYSTARS.