The Benefits of Prefabrication in Data Centers

Prefabrication is a process in which data center critical components are engineered, manufactured, and tested off-site before they are delivered and integrated into the data center facility. Traditionally, this material assembly and installation work is performed on site by local contractors, however, an industrywide shortage of this skilled labor has resulted in a snowball effect of schedule delays and increased project costs. This untenable situation has given rise to a forward-thinking approach that provides relief to the local labor challenge while simultaneously enhancing quality, deployment speed, and cost efficiency. In this article, we explore how prefabrication is quickly becoming a sustainable solution to meet the growing demands of the data center market.

What is Prefabrication?

Prefabricated solutions for data centers can come in several forms. Some are complete modular structures with embedded network technology and power and cooling equipment, and others are component-based like customized racking structures or HVAC equipment prefabricated and delivered on a skid foundation.  

Containerized data centers are typically fully operable, plug-and-play systems housed in a shipping container or similar structure. This type of standalone solution can be ideal for fast deployment scenarios, such as for disaster recovery or temporary capacity boosts. Containerized data centers are also often used for Edge deployment, thereby increasing computing power closer to the application need or end-user operations.  

Prefabricated modular systems are designed as scalable, long-term solutions utilized in both existing facilities and new data center construction, particularly larger cloud service providers and colocation facilities. As a construction solution for these data centers, modular prefabrication can be system or component-based, comprised of predesigned critical infrastructure such as containment systems, piping assemblies, and power and cooling equipment that is assembled off-site and delivered on a skid, ready for simplified installation.  

Collectively, prefabricated data centers and prefabricated modular systems are constructed off-site in a controlled environment, as opposed to being built on-site by local skilled labor. Embracing a blended prefabrication strategy enables data center operators and builders to take advantage of added labor resources working on complex, high-performance equipment, often with specialized tools, in conditions that reinforce attention to design specifications, safety, and quality control.

Benefits of Prefabrication  

Scalability and Flexibility

One of the key advantages of prefabricated solutions is the ability to grow with your business. Whether you need additional computing capacity or want to expand to new locations, prefabricated modules can efficiently be transported and installed at different sites.

• Standardized Designs: Using standardized prefabricated modules, data center operators can replicate systems, scaling operations as needed.

• Planning Ahead: Pre-designed and fabricated systems can help builders stay ahead of long-lead times for vital equipment and secure materials already in high demand.  

• Relocation Flexibility: Prefabricated modules can also be redirected to a new site, adding flexibility for data center operators with shifting needs or expansion into new markets.

Deployment Speed and Cost-Effectiveness

The off-site construction of prefabricated modular solutions expands your labor force beyond what is on-site, resulting in several financial and operational benefits:

• Faster Deployment: Shifting a percentage of the work to be completed off-site adds skilled labor resources to your project that may not otherwise be accessible, thereby shortening construction schedules and accelerating the path to revenue.

• Reduced Labor Costs: Prefabrication work completed off-site in a factory setting can offset on-site labor, compounded by faster completion, an important contributor to cost savings.

• Material Management and Waste: Prefabrication in a controlled environment allows for more precise inventory management and material use, reducing waste and associated costs.

Reliability and Performance

Prefabricated modular data center systems undergo rigorous quality control and testing in a controlled environment before they are delivered to the customer. This ensures that they meet strict performance standards, on-site testing, and are prepared for the high demands of mission critical environments.

• Quality Assurance: Prefabrication ensures consistent quality across all data center modules, mitigating defects and improving long-term performance.

• Design Precision: Modern data centers require the highest level of precision in the integrated systems operating the facilities, as a single flaw can have a catastrophic impact. Off-Site prefabrication enables skilled technicians with state-of-the-art tools to ensure accuracy from design through fabrication.      

• Mitigated Downtime Risk: The precise assembly and pre-testing of prefabricated modules help safeguard against unforeseen downtime in operations.

Energy Efficiency and Sustainability

Energy efficiency is more important than ever, especially as data centers are challenged by higher density server racks requiring more power and increased energy consumption.  

Modular data center solutions are designed with energy efficiency in mind:

• Energy-Efficient Cooling Systems: 30-55% of a data center’s energy is spent on cooling. Advanced cooling systems are integrated during the prefabrication process, ensuring that the data center operates at optimal energy levels and reducing the total cost of ownership by cutting down on energy consumption.

• Sustainability: By fabricating off-site, it is easier to embrace sustainability measures and use recycled materials, while also minimizing waste. Additionally, prefabricated data centers require less visits to the job site for construction, reducing overall carbon emissions from transportation.

Safety and Construction Labor

Fabrication facilities use advanced technology and specialized heavy machinery to transform the raw materials into customized systems, adding support to the existing “boots on the ground” amidst extensive labor shortages in the construction industry.

• Labor Challenges: Since many data centers are built in rural markets where land and power are less expensive, there is often not sufficient, experienced local labor to meet the new construction demand. Prefabrication solutions expand your work force beyond those geographic limits, also adding skilled labor experienced with building complex systems.  

• Safety: Safety is paramount for any data center builder, and prefabricated solutions can reduce complicated assembly and installation scenarios for on-site labor. Furthermore, prefabrication takes place in a controlled environment which also adds focus on safety and improved work conditions.

• Specialized Equipment: Off-site prefabrication enables the use of large, specialized equipment and welding systems that enhance quality control and the speed and scale of the manufacturing process.      

The Bottom Line

Meeting the needs of an increasingly digital society and economy in today’s modern world cannot be met without progressive construction methods. Prefabrication addresses labor shortages and accelerates project timelines, blending on-site and off-site skilled labor resources to remove geographic constraints and maintain a competitive edge.

When applied programmatically, prefabrication enhances deployment speed, scalability, and supply chain reliability. Furthermore, the controlled environment reduces unnecessary waste and ensures high-quality, energy efficient, precision-built systems that are essential to data center performance. Embracing modular construction as part of your data center construction strategy is a forward-thinking approach to build the critical infrastructure our digital society depends on.          

Work with Legence today!

‍