The U.S. has more than 2,800 data centers – the highest number of any country. Yet demand for new facilities shows no signs of slowing down. Meeting market demand requires getting data centers designed, constructed and operational as fast as possible.
At the same time, building data centers is a complex process that demands meticulous planning and coordination. Traditional construction methods, often plagued by unexpected weather, rework and unforeseen costs, are not synonymous with speed. As a result, developers are challenging traditional data center design and construction methods, and many are finding that prefabrication is the solution.
Why Prefabrication?
Prefabricated – or precast – concrete is manufactured in a controlled environment and delivered to the job site, reducing overall project risk by improving cost and schedule certainty and enabling greater supply chain control.
From flexibility in design to rapid delivery, prefabricated concrete aligns with the unique requirements of data center design and construction. Here are five reasons why:
1. Early Alignment and Efficient Design
Prefabrication manufacturers utilize design-for-manufacturing-logistics-and-assembly (DfMLA) practices. DfMLA brings together stakeholders – including owners, architects, engineers, and contractors – early to collaborate and optimize the design for manufacturing and assembly. DfMLA aligns the team on project vision, saving time and money.
In addition to improving budget predictability, DfMLA can reduce timelines by as much as 40%, making data centers operational sooner than those built with traditional methods. Early operational readiness helps developers meet market demand, boost profitability and capitalize on growth opportunities.
2. Design Flexibility
Contrary to the misconceptions of some, prefabricated concrete offers design flexibility, allowing developers to customize components for operational efficiency and future expansion with minimal disruption.
Prefabricated structural systems can accommodate the large open spans essential for housing servers, cooling systems, and other critical equipment. Functional elements, such as insulation, ventilation and mechanical openings, are incorporated into the design. For example, integrating mechanical platforms into the structural systems can accelerate construction. Embedded metal framing simplifies pipe and equipment installation by making it easier to hang and route systems. Platforms designed with movable grates allow for easy maintenance access and fewer roof penetrations, which enhance weatherproofing and optimize long-term system performance.
These flexible design options, along with the sequencing of platform installation with the chillers, streamline coordination and reduce construction by months.
3. Durability and Resilience to Extreme Events
Prefabricated concrete is durable and highly resistant to physical damage from weather, unexpected events, fire, and environmental conditions. It is also difficult to breach, which fortifies equipment and data security.
Due to its low-maintenance and long lifespan, prefabricated concrete reduces the total cost of ownership by minimizing the need for frequent maintenance and repairs.
4. Sustainability
Prefabricated concrete integrates sustainable building practices into data center construction in multiple ways. By manufacturing components off-site, it reduces disruptions on the job site and minimizes noise, dust, and waste.
Through the use of lower-carbon concrete mixes and manufacturing in environmentally controlled facilities, prefabrication helps developers actively reduce Scope 3 emissions. Furthermore, off-site construction presents the opportunity to utilize entirely renewable energy in the manufacturing process of all prefabricated concrete products.
5. Reduced Risk
Numerous factors, such as labor shortages, unpredictable weather, and material inconsistencies, can lead to costly delays and budget overruns.
Prefabricating building components off-site reduces the reliance on specialized labor at the job site, lowering the risk of accidents and addressing the challenge of securing skilled labor in times of shortage.
By adhering to stringent quality standards, prefabricated components minimize the likelihood of defects or inconsistencies. These components, delivered ready for installation, expedite construction timelines and mitigate delays caused by weather conditions or labor shortages. Moreover, the controlled manufacturing process reduces material wastage and errors, ensuring better cost predictability and eliminating budget overruns resulting from unforeseen issues like material scarcities or design alterations.
A New Data Center Construction Standard
Prefabrication sets a new benchmark for data center construction, expediting timelines, ensuring precision in manufacturing, and incorporating eco-friendly practices.
In a rapidly evolving market, data center developers seek speed, efficiency, and value. Prefabricated concrete delivers on all fronts, ensuring swift construction, enhanced operational efficiency, and long-lasting infrastructure.
