Data Center Construction: What to Know

Article

Introduction

As AI, IoT, Streaming Services, and Cloud Computing dramatically increase the need for safe, secure, and reliable data storage and distribution, the race is on to build out the nation’s digital infrastructure. In this feature, we’ll discuss the many areas where experienced builders can make a positive impact for developers at each stage of the data center construction process.

Data Center Site Selection

While a data center developer typically takes the lead in site selection, builders can contribute valuable expertise to help in the process. We can weigh in on the parcel itself, informing developers about the slope, water runoff, land stability, and more in terms of potential positive or negative effects on overall performance.

Builders often have trusted relationships with local municipalities; we can help expedite zoning and permitting approvals, while informing stakeholders on the potential the project will bring to the community. Land selection, power supply, and intended usage will also impact the type of construction materials used down the line, including choices between specific concrete and steel products in the foundation and critical infrastructure.

North Lake Tech Center

Lean Data Center Construction

No two data center projects are exactly the same, and the common mantra for developers and builders is to continually improve construction efficiency. To reach ambitious efficiency goals, Building Information Modeling (BIM) needs to take place as early as possible, even during the preconstruction phase, to ensure that an efficient and cost-effective data center can be implemented for the owner and future tenants.

BIM includes cloud-based, integrated data management, 3D modeling, and collaborative project execution. This technology streamlines workflow processes by eliminating silos between architects, engineers, general contractors, subcontractors, inspectors, and regulators while spotting potential clashes in an instant, allowing proper coordination to be done and corrected proactively.

When considering all of the MEP and structural components of a data center and its requirements, even the most minor decisions will have major impacts down the line, such as choosing one type of wall panel, adhesive, fire coating, or server rack over another. During construction, certain product or material selections might make sense based upon market pricing or availability, but could result in incremental costs and performance impacts down the line, such as conflicts with engineering or shorter than desired performance. This is where BIM’s long-term modeling and projections help developers make informed decisions.

BIM helps stakeholders identify and resolve conflicts at the earliest stages of development. BIM has evolved beyond 3D to include dimensions like 4D (scheduling), 5D (cost), 6D (sustainability), and 7D (facility management), with emerging frameworks exploring even more dimensions. So in this capacity, the construction partner can provide expert counsel that will affect the entire project from planning and construction throughout operations, retrofits, and future expansion.

Building a Data Center

Once design and engineering plans are in place for a data center project, the general contractor takes the baton to clear the land, pour the foundation, set up the infrastructure, and build the shell to house the operating components and protect mission-critical operations from routine weather events, natural disasters, and security threats.

While construction is the last phase of the process before operation, bringing the builder in at the very beginning of planning can help improve efficiency, control costs, streamline site selection, zoning, permits, approvals, and ensure safety during the build and throughout operation. Data centers are a long-term investment for the property owner/manager, so making the right decisions upfront can ensure long-term project sustainability and profitability.

Choices made during the construction of a data center will impact its ultimate performance, longevity, and profitability. Data Center performance includes (but is not limited to) site security, network security, climate control and fire safety, power supply and redundancy, and operational efficiency. Supply chain management is an essential part of the construction process; many structural components have long lead times, so it’s essential to plan thoroughly from the earliest stages to keep schedules on track and avoid material swap-outs that could compromise performance down the line.

Edged Chicago Data Center

Data Center Infrastructure

To furnish the inside of the shell, the developer has several options to secure core electrical, plumbing, and HVAC components, and highly specialized racks and cooling equipment. OFCI (owner furnished, contractor installed) and CFCI (contractor furnished, contractor installed) are the two most common procurement strategies.

  • OFCI allows for consistency of equipment nationwide, while CFCI can often overcome backorders and supply chain issues.
  • The more intricate the component, the longer the lead time is usually in place to ensure it’s on-site just in time for installation.

Data Center Reliable Energy Sources

Data Centers are designed to be always on, where unexpected downtime can cause catastrophic losses of data, money, functionality, and/or business operations. Allowable downtime varies depending on the type of facility. Tier I data centers allow up to 29 hours of downtime per year, whereas Tier IV allows only 26 minutes. Some Tier III facilities FCL has built guarantee only 1.6 hours of downtime all year, which is less than 16 seconds of downtime per day.

For this reason, both physical and digital infrastructure must deliver seamless redundancy and backup systems. Central to this is the power supply.

Data centers have tremendous amounts of power demand, so most sites must deploy several sources of energy, including, when appropriate, connections to the local energy grid that also powers homes and businesses in the region. Many data centers supplement or fully operate on additional and backup power sources, including nuclear energy, wind, solar, hydroelectric, and fossil fuel. When one source is compromised or underperforms, others are at the ready to kick in or upscale to keep all servers fully operational. For example, if a data center is only able to draw 3-9MW from the available grid power, it will need an on-site substation to generate an additional 10-20MW. The availability of this substation, likely paired with a fossil-fueled backup generator, allows the developer to ramp up as needed to onboard new tenants.

Data Center Site Security

Beyond power outages, other threats to the power supply must be factored into the design and construction of a facility. Physical barriers must be in place to prevent vehicles and drones from crashing into the core facility or power source. This can include gates, wheel spikes, high-security fencing, fortified mantrap entrances, and anti-ram barriers. Landscaping can provide several functional and aesthetic uses. Ponds, hills, ditches, trees, and shrubbery can obscure facilities from street and aerial views while also making the site visually pleasing to authorized employees and visitors. These components also block threatening vehicles and aircraft from being able to impact and damage the facility. Natural shade can help cool facilities in the summer, while advanced water runoff systems can help prevent flooding during heavy rains.

The actual shell of the structure serves a variety of functional, visual, and security purposes. Internal protection includes the ability to house and cool servers, cabling, fire protection, plumbing, lighting, and electrical systems. External protection takes on snow, wind, rain, falling branches, and security threats.

Conclusion

These are just a few of the ways a qualified data center building contractor can add value to the project from the earliest stages of planning onward. See below for examples of FCL Builder’s vast portfolio of projects, including some prominent data centers.