ENCLOSURES Prefabricated critical T


here is no denying it; we are experiencing a new, digital, industrial  intelligence (AI) engine. Everything around us is changing, either as private or business users / consumers, we are integrating digital AI tools in our life. What remains hidden to the naked eye, is what makes the AI run. This is where we submerge ourselves into a world of critical infrastructure, where engineers design and innovate power and cooling architectures, enabling the AI heartbeat to keep pounding.


The servers are housed inside racks, exceeding 100kW of power consumption each. Just a short while ago, we were seeing densities of 4-15kW, making this a 10x increase in density. The overall power demand has skyrocketed, presenting the unique challenge, building new data centres with 10’s and 100’s of MW for AI in a short time span. All whilst continuing to densify the critical infrastructure.


Prefabrication lends itself as a construction methodology to meet industry demands for high volumes and rapid deployment. Another advantage of prefabricated power modules is the  complexity. These modules are designed and built off-site in a controlled environment, which minimises errors and delays that can affect traditional on-site construction. By the time the modules arrive at the installation site, they are fully tested and ready for integration, allowing a seamless and trouble-free deployment.


The controlled manufacturing environment enables better resource management and bulk purchasing of materials. Additionally, the reduced on-site labour and shorter construction timelines contribute to improved overall cost predictability and lowers the risk of budget overruns. The design of prefabricated modules  requirements, including different power  with existing systems. Such designs can then be deployed at a large scale (high volume of modules). This allows a pay-as-you-grow approach and data centres can quickly expand their capacity by adding more


20 MARCH 2025 | ELECTRONICS FOR ENGINEERS


infrastructure – powering the IT world


Krešimir Krpan, senior director, global business development and solution architecture, Infrastructure Solutions at Vertiv


prefabricated modules as the demand grows.


There are several prefabricated systems in the data centre industry: • All–in–one modules • Fully prefabricated data centres • Prefabricated building blocks: • Power Modules • Whitespace infrastructure modules • hydro skids/modules


On a larger scale, data centres of 10MW to 100MW, the prevailing construction methodology utilises prefabricated building blocks; power modules / skids typically include medium and low voltage switchboards, transformers, uninterruptible power supplies (UPS) and batteries, as well as cooling units for heat management. In this case the individual building block size  generator size. Typical sizes are two to three MW, so for example, a 40MW data centre can be powered by 5 x (4+1) 2MW Power module topology.


Instead of installing this infrastructure on site and working on platforms, these rapidly deployable building blocks provide  IT Infrastructure modules are deployed within the data hall and typically include cable trays / ladders, busbars, lights, hot/ cold aisle containment, and for high density, Secondary Fluid Network (SFN), piping that connects to the liquid cooled racks.


Prefabricated modules also help reduce carbon footprint. The controlled manufacturing process generates less waste in comparison to traditional construction methods. As a construction  over concrete and further improvements can be achieved by utilising mass timber as module material. The transport element can also be reduced by building modules closer to the site location. Many prefabricated providers have multiple manufacturing locations, thus reducing the environmental impact of transport by manufacturing in a convenient location.


Final Insights and Future Market Outlook


Prefabrication as a key element of construction is now omnipresent in the data centre industry. The speed of change and increase of capacity demand will continue to bring more players into the prefabricated market. The challenge is no longer on who can do it, but rather at what scale, speed and level of customisation prefabricated modules and other building blocks be manufactured.


Liquid cooling demand is also expected to increase IT infrastructure prefabrication,  as temporary assembly lines set up directly on building sites.


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