Case Study - Design & Prefab | Brown & Moodie website

Data Centre – Modular Prefabricated Piping System

Project Overview

Brown & Moodie was engaged through pipework & design to support the expansion of a large-scale data centre utilising rooftop air-cooled chillers connected to a water-based cooling system.
Our scope included engineering development of a fully modular piping network designed for off-site prefabrication in our facilities - enabling controlled assembly, improved accuracy, and a streamline with reduced site time system installation.

The scope covered multiple levels and corridors within the data centre, requiring high-precision modelling, coordination with other trades, and the detailed prefabrication documentation to ensure compatibility with existing systems.

Client: Climatech Group

Industry: HVAC / Technology

Location: NSW, Australia

Project Duration: 6 months

Scope: Engineering and delivery of a high quality modular piping network designed for off-site prefabrication and installation across multiple levels and corridors of a large data centre.

The Objective

The project aimed to improve accuracy, efficiency, and risk mitigation in 1st pass across both design and installation phases, with key objectives including:

Enhance communication and documentation
Improve system performance
Reduce manual and human error
Increase traceability and workflow efficiency
Improve the quality of the installation
Improve working conditions and reduce waste
Enhance quality and automate reporting processes
Reduce site labour hours & personnel

Challenges

The project presented several technical and operational challenges, including:

Integration with legacy systems
Tight program deadlines and limited budget
Complex constructability and accuracy requirements
Coordination with multiple trades in constrained environments
Maintaining system compatibility and organisation across levels and areas
Procurement and staging under strict timelines

Solutions and approach

To manage complexity and meet program requirements, Brown & Moodie implemented a highly structured digital-first workflow.

Building Information Modelling (BIM): Our team developed precise 3D components in Revit, ensuring fabrication-ready accuracy across all system elements.
Detailed prefabrication documentation: For each stage of off-site fabrication, we produced comprehensive sheet sets outlining assembly, installation sequences, and quality verification steps.
Data-rich model & automated reporting: The model was integrated with Microsoft Access and Power BI to automate BOMs, cut lists, load schedules, and procurement reporting.
Cloud-based CDE with 3D barcodes: Files were stored within a structured Common Data Environment, organised by level, area, zone, and system. Each element was linked via 3D barcode for fast retrieval, tracking, and quality assurance.

This approach ensured complete alignment between design intent, fabrication sequencing, and onsite installation.

Results and Impact

The project delivered significant improvements in precision, safety, and installation efficiency:

Highly accurate fabrication-focused modelling reduced onsite rework and delays
Early identification of issues through detailed documentation improved safety and workflow
Automated procurement and reporting increased efficiency and reduced manual errors
Standardised documentation and procedures enhanced lifecycle quality and traceability
QR-linked data environments improved long-term accessibility and asset management