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Assessment of Construction Techniques and Structural Development in Two Data Center Facilities in India

Surekha Manchakrao Thoke1 , Dr. A. P. Wadekar2 , Dr. D. N. Kakade3

1PG Student, Masters of Technology in Structural Engineering – P.E.S College of Engineering, Chhatrapati Sambhajinaga, M.S.

2Principal & Professor - P.E.S College of Engineering, Chhatrapati Sambhajinagar, M.S.

3Associate Professor and Head of Civil Engineering Department - P.E.S College of Engineering, Chhatrapati Sambhajinagar,M.S. ***

Abstract - In today's digital age, the need for data centers in India is growing fast due to the rise of 5G, cloud computing, and the Digital India mission. For websites, apps, and online services, data centers special buildings where computer servers store and oversee data These buildings have to be robust, safe, energy-efficient, running without stopping capable. Two data centres, DC 1 andDC2,constructedinPune, are compared in this study. Made using conventional concrete techniques and air-based cooling systems, DC 1 is Modern precast materials and cutting-edge liquid cooling are used in the construction of DC 2 to save energy. Built to Tier III criteria, both centres feature backup systems designed to run even during maintenance or breakdowns. Their structure, foundation, cooling, fire safety, energy consumption, and future expansion simplicity are compared in this paper. The study is grounded on visual observationandreliablepublished sources since inside data was not accessible. While DC 1 is strong and dependable, DC 2 is more energy-efficient and better for future expansion according the comparison. Engineers and planners can use these findings to enhance the construction of data centres in India in the future.

Keywords : Data centers, Construction comparison, Structural design, Modular construction.

1. INTRODUCTION

Overthepasttenyears,thedigitaleconomyhasexpanded rapidlyandcorrespondinglyincreaseddemandforscalable, energy-efficient data centres. Ensuring 24/7 connectivity, data processing, and storage for industries including banking, healthcare, education, and e-commerce, these facilities constitute the operational backbone of contemporary infrastructure [1]. Demand for very strong andefficient data centres is morethan everas businesses migratetocloud-basedsolutionsandinternettrafficrises.

Particularly India is seeing a fast change in her digital infrastructure.Datacentresarenowbeingbuiltallaround thenationthanksinlargeparttoinitiativessuchasDigital India and the deployment of 5G technologies [1]. The exponentialriseinreal-timeapplications,mobiledatausage, and IoT devices is severely taxing current infrastructure, thusdesignandconstructionofnext-generationdatacentres becomeanationalfocus[2],[11].

Complex,high-performancestructures,datacentresdemand accuracy in structural engineering, architectural planning, mechanicalsystems,andenvironmentalsustainability.Their designallowsforadvancedsecuritysystems[3],[7],cooling equipment, large server racks, and continuous power supplies [3]. Recent research underline the need of highperformancebuildingmaterialsincludingprecastconcrete and steel frameworks to satisfy these needs [5], [8]. Furthermore under increasing focus for enhancing build quality and lowering construction times are modular and prefabricatedbuildingmethods[5],[6].

Oftenaccountingforupto40%oftotalenergyconsumption [2], [4], cooling systems are essential component of data centredesign.Studieshaveindicatedthatalternativessuch as liquid immersion and direct-to chip cooling are now regarded as necessary for lowering Power Usage Effectiveness(PUE)ratios[3],[4],[17],sinceconventional air-basedcoolingsystemsareinsufficientforhigh-density server environments. Moreover, the application of smart HVACsystemscompliantwithASHRAEcriteriaandthermal energyrecoveryisbecomingrathercommon[17].

Anothermainissueisthesecurityofdatacentres,especially inareaspronetodisasters.Recentresearchhasunderlined inparticulartheintegrationofseismic-resistantbuildings, baseisolators,andadvancedfireprotectionsystems such as FM200 and Inergen gas suppression necessary to reducestructuralandoperationalhazards[7],[9],[18],[19].

Regarding classification, global frameworks including the TIA-942 standard and the Tier system of the Uptime Instituteofferthoroughdirectionsforbuildingfault-tolerant and resilient data centres [14], [15], [26], [27]. In India's metropolitanITcentres,TierIIIandTierIVfacilities which supportconcurrentmaintainabilityandfaulttolerance are growinglyprevalent[15],[30].Furthermoreensuringthat facilities are structurally sound and environmentally compliantareIndianbuildingrules(e.g.,IS456andIS875) andmunicipalcodes[18],[24],[28].

Green building techniques have also become rather important recently.UsingLEEDguidelinesand ISO50001 energymanagementstandardsisenablingnewdatacentre projectstoreachhighersustainabilityandenergyefficiency

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[20], [21], [31], [33]. These steps not only lower carbon footprintbutalsomaximiselong-termrunningcosts.

Althoughnationalandinternationalstandardsabound,the application of construction best practices differs greatly betweenprojects.Inordertoassessthebuildingtechniques, structural systems, fire safety, energy management, and design efficiency, this paper thus offers a comparative analysisoftwodatacentressituatedinPune,India:DC1and DC2.AlthoughbothdatacentresfallunderTierIII/IV,their building schedule,scalability,andsystem integrationvary greatly.Topinpointstrengths,difficulties,andbestpractices, the study combines visual observation, publicly available data,andevaluationsupportedbyliterature.

This paper attempts to add to the growing body of knowledge on sustainable and resilient data centre construction in developing nations like India by matching thisstudywiththemostrecentbuildingandinfrastructure trendsrecordedinacademicliterature[1]–[20].

2. METHODOLOGY

2.1 Selection Criteria of DC 1 and DC 2

Thisstudycomparestworeal-worlddatacenters DC1and DC2 basedonobservableconstructioncharacteristicsand publiclyavailableinformation

 DC 1 is a conventionally constructed data center using on-site concrete casting and traditional structuralpractices.

 DC2utilizesaprecastconcreteapproach,featuring modular and pre-engineered components assembledon-site.

Thesetwocenterswereselectedbasedonsimilaritiesin:

 Operationalscale

 Geographicalandenvironmentalconditions

 Tierclassification(TierIIIorabove)

 Visibilityandaccesstoexternalobservation

Selection was also guided by the ability to identify key construction differences visually and through publicly accessibleresourcessuchasarchitecturalpublicationsand mediaarticles.

2.2 Parameters for Comparison

Toensureconsistencyandrelevance,bothdatacenters wereevaluatedbasedonthefollowingparameters:

 Construction Methodology

On-sitetraditionalvs.precastmodulartechniques

 Construction Timeline

Approximatedurationbasedonpublicrecordsor visualevidence

 Material Handling & Usage

Typeandqualityofmaterials(asobservable), uniformityofconstruction



Scalability and Modularity

Visibleprovisionsforfutureexpansion,modular units

Structural and Seismic Features

Externalsignsofearthquakeresistance(e.g.,base isolationpads,expansionjoints)

Fire Safety Provisions

Fire-resistantmaterials,placementoffireexits, separationwalls

Cooling and Ventilation Layout

RooftopHVACunits,airexhausts,visible ductworksystems

 Backup and Redundancy Systems

Generatorrooms,dualutilityfeeds,redundant coolingunitsvisibleonsite

Theseparameterswerechosenfortheirrelevancetoboth structural quality and data center efficiency, and because theycouldbeassessedwithoutinternalaccess.

2.3 Data Collection Sources

Given that internal documentation or direct access to the facilitieswasunavailable,thefollowing non-invasive data sources wereused:

 On-Site External Observation

Multiplevisitsweremadetoobserveconstruction detailsandinfrastructurelayoutsexternally.

 Public Domain Visuals

Photos and videos from company websites, constructionnews,andpublishedmediawereused foranalysis.

 Literature Review

Academic studies, case reports, and industryspecificpublicationshelpedframethecomparison criteria.

 Expert Opinions (Informal)

Generalinsightswereobtainedfromcivilengineers and industry professionals through off-site, informaldiscussions.

2.4 Limitations of the Study

The methodology, while groundedinrealistic observation andliterature,comeswithseverallimitations:

 No Access to Internal Documents

Architectural blueprints, cost details, structural calculations,ortechnicalreportswerenotavailable.

 Observation-Based Judgments

Manyevaluations(likematerialtypeormodularity) are based on visual clues, not confirmed documentation.

 Estimation-Based Assumptions

Construction timelines, design intentions, or performance metrics were estimated based on

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publiclyaccessibleinformationandmaynotreflect exactvalues.

 Lack of Operational Data

Keydatalikeuptime,coolingefficiency(PUE),and loadmanagementwerenotpartofthisstudydueto accessconstraints.

 Site-Specific Findings

The results may not apply universally to all data centers, as they are based on two specific case examples.

3. OVERVIEW OF DATA CENTERS

1) 3.1 Data Center 1 (DC 1)

Table 1 : DC1Parameters

Section Details

3.1.1 Location, Owner, and Size

-LocatedinPune,withinadedicated ITzone

-Ownedbyamultinationaltechnology company(cloudandenterprise services)

-Built-uparea:approximately45,000–50,000sq.ft.

-Mainstructure:G+4floors

-Includessecurityunit,electrical substation,andmechanicalyard

3.1.2 Structural System and Materials

-Cast-in-situreinforcedconcrete (RCC)frame

-RCcolumnsandbeamswithflat slabsanddroppanels

-AACorconcreteblockmasonryfor infillwalls

-Fire-rateddoorsandpartitions throughout

-IntegratedMEPrisersandcabletrays inslabs

-Increasedreinforcementinloadbearingzones

-Fire-retardantcoatingsonexterior walls

3.1.5 Energy Efficiency Features

-Securityandadminblockconnected butisolatedfromserverblock

-Externalzoningincludesramps,DG platforms,transformers,andsecure fencing

-Verticalshadingfinsand cantileveredroofprojections

-RooftopHVACandair-cooledchiller unitswithVFDs

-Double-glazedfaçadepanelsfor reducedsolargain

-Smartlightingandmotionsensorsin non-criticalareas

3.1.3 Foundation Details

3.1.4 Layout and Zoning

-Likelydeeppilefoundationsystem

-Suitableforheavyserverand equipmentloads

-SupportsrooftopHVACand generatorplatforms

-Providesstructuralsafetyinsoftsoil conditions

-Possibleraftfoundationundercore functionalzones

-Centralizedserverhallonupper floors

-LowerfloorslikelycontainUPS, electrical,andchillerrooms

-Separateservicecorridorsandfire escapestaircases

3.1.6 Tier Classification

-DesignedasaTierIIIfacility(Uptime Instituteclassification)

-DualUPSsystemsanddualdiesel generators

-N+1coolingredundancy configuration

-Concurrentmaintainabilityfeatures

-Likelydualnetworkpathsandfaulttolerantarchitecture

-Ensures99.982%annualuptime

2) 3.2 Data Center 2 (DC 2)

Table 2 : DC2Parameters

Section

3.2.1 Location, Owner, and Size

3.2.2 Structural System and Materials

•LocatedinPune

Details

•Operatedbyadigitalinfrastructure servicesprovider

•Built-uparea:approx.60,000–65,000sq. ft.

•Structure:G+2floors

•Includesutilitybuildings(generators, coolingunits,adminoffices)

•Independent,securedplotwithlimited access

•DesignedtomeetTierIVdatacenter standards

•Hybridstructuralsystem

•Precastreinforcedconcreteforbeams, slabs,andcolumns

•Cast-in-situRCCforstaircoresand serviceshafts

•Steelplatformsusedonrooftopsfor mechanicalunits

•Raisedflooringforcablingandairflow

•Highload-bearingslabsforserver weight

•Fire-ratedpartitionsandceilings

•Vibrationisolationcomponentsfor sensitiveequipment

3.2.3 Foundation Details

•Raftfoundationwithdeeppilesin heavy-loadzones

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•Supportshighpointloadsand equipmentstress

•Designedforseismicresilience

•Reducesdifferentialsettlement

•Waterproofmembranesapplied

•Includesvibrationdampenersand isolationpadsforutilityducts

3.2.4 Layout and Zoning

•Groundfloor:mechanicalandelectrical systems(UPS,powerunits)

•Firstfloor:serverhallsandITcontrol centers

•Secondfloor:storage,networksystems, anddisasterrecoveryzones

•Rooftop:HVACunits,coolingtowers, supportsystems

•Segregatedservicecorridorsand personnelaccess

•Clearlydefinedemergencyexitpaths

•Designedforoperationalsafetyand maintainability

Construction Timeline Estimated constructiontime: 12-15monthsfrom groundbreakingto operationallaunch

Cost of Construction

Structural Design

3.2.5 Energy Efficiency Features

3.2.6 Tier Classification

•Advancedcoolingsystems(likelyliquid ordirect-to-chip)

•Insulatedpipelinesandthermalbarriers

•Rooftopsolarpanelsforsupplementary power

•Smartmonitoringsystemsforenergy andthermalperformance

•Energy-efficientlightingandmotion sensors

•Smartbuildingcontrolsystems

•Alignedwithmoderngreenbuilding practices

•TierIVinfrastructurestandard(based onvisiblesystems)

•2Nredundancyinpowerandcooling systems

•Concurrentmaintainabilitywithout operationaldisruption

•Fault-tolerantarchitecture

•Multiplebackupsystems(generators, UPS,cooling)

•Designedforuninterrupteduptimeand highreliability

4. PARAMETERS OF COMPARISON

Table 3 : ComparisonParameters

Parameter DC 1 DC 2

Location & Geotechnical Conditions

Foundation Type

Highercostdueto incorporationof extensivesecurity andstructuralloadbearing requirementsfora high-tierdesign

Precastconcreteand steelusedfor structuralelements, withraisedfloors andseismic-resistant systems

Pilefoundations withreinforced concreteraftfor betterload distributionand seismicsafety

Materials Used Concrete,steel,glass withuseoffireresistantand soundproofing materialsforserver areas

Fire Safety

Comprehensivefire suppressionsystem, includingFM200and Inergensystemsfor quickresponse

Seismic and Wind Load Design

LocatedinPunewith favorablesoil conditionsfor construction; moderateriskfor seismicactivity

LocatedinPune, independentplot withadequate geotechnical featuresand foundationdesigned forhigh-loadbearing requirements

HVAC & MEP Integration

Designedto withstandseismic forces;reinforced wallsandbase isolatorsincritical zones

AdvancedHVAC systemswith redundantcooling solutions, centralized mechanicalsystems forefficiency

Redundancy & TierIV:2N

Estimated constructiontime: 18-24months, involvingmodular constructionfor flexiblesetup

ModeratetoHigh costwithan emphasison modularsystems andenergy efficiencyfeatures

Hybridapproach: Precastconcrete, RCC,andsteel; designedfor modularityand heavyequipment

Likelyraft foundationwith deeppilesinheavy loadzones, enhancedwith waterproofingand vibrationdampeners

Precastconcrete, steel,RCC,fire-rated partitions,and modular components designedfor flexibility

Similarfiresafety features,including FM200andInergen; advancedfire-rated partitionsand smokecontrol systems

Incorporates seismic-resistant designswith reinforcedconcrete andvibration isolationsystems

Integratedwith direct-to-chip coolingsystems; highlyefficient HVACintegration withdedicated coolingsystems

TierIV:Similar

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Uptime Tier redundancywith dualpowerfeeds, backupgenerators, andconcurrent maintainability

Cooling Techniques

Sustainable Practices (e.g., LEED certification)

Likelyair-cooling withpotentialchilled waterorliquid coolingsystemsfor energyefficiency

NoformalLEED certification,but featuresinclude energy-efficient lightingandsmart monitoring

Power Backup Infrastructure DualN+1power feeds,backupdiesel generators,and multipleUPS systemsforpower redundancy

Scalability / Expandability Designedfor modulargrowth withspacefor additionalracksand powerexpansion

redundancyand uptimefeatures, ensuring99.995% uptimewithfaulttolerantsystems

Liquidimmersion coolingordirect-tochipcooling, reducingenergy consumptionand enhancingheat dissipation

NoformalLEED certification,but includessolar panels,energyefficientHVAC,and thermalinsulation

Similarbackup infrastructurewith dualN+1power feedsand generators,ensuring zerodowntime duringpowerfailure

Highlyscalablewith modulardesign, providing incremental expansion possibilitieswithout disrupting operations

Space Utilization Highlyoptimized floorplanswithclear zoningforspecific functions,allowing forflexibleuseof space

Similarefficientuse ofspacewith dedicatedareasfor cooling,IT equipment,and backupsystems

3) 5. Results and Discussion

5.1 Differences and Similarities

Differences:

 ConstructionTimeline:

DC 1 was built faster (12–15 months) due to its focused RCC design. DC 2 took longer (18–24 months) because of its modular setup and future expansionplanning.

 CostofConstruction:

DC1hadhigherinitialcostsduetorobustmaterials andadvancedsecurity.DC2wasmoreeconomical



initially but may require greater long-term investmentforscalability.

CoolingTechniques:

DC1usestraditional air-cooledandchilledwater systems.DC2adoptsmoderntechniqueslikeliquid immersion and direct-to-chip cooling, improving energyefficiency.

PowerBackupInfrastructure:

Both use N+1 power redundancy, but DC 2 has a more advanced backup system optimized for flexibleenergyuseandcoolingsupport.



Seismic and Wind Load Design:

DC 1 uses base isolators for seismic safety. DC 2 features vibration isolation systems, offering greateradaptabilitytoenvironmentalloads.

Similarities:



Redundancy&UptimeTier:

Both comply with Tier IV standards, offering 99.995%uptimethroughfullyredundantandfaulttolerantsystems.

 StructuralDesign:

Each uses concrete, steel, and fire-resistant materialsandisdesignedtosupportheavyITloads andinfrastructuredemands.



FireSafety:

Both facilities employ FM200 and Inergen gas suppressionsystemstoensurerapidfireresponse andprotectionofcriticalequipment.

5.2 Which Data Center is More Efficient and Why

Becauseofitssophisticatedcoolingmethodsandmodular design,whichprioritisesscalabilityandenergyconservation, DC2seemstobemoreefficient.ComparedtoDC1,which usesconventionalaircoolingsystems,DC2'suseofliquid immersion cooling greatly improves energy efficiency by lowering the PUE (Power Usage Effectiveness) ratio. Furthermore, DC 2's modular design makes expansion simple, which improves space utilisation and long-term operationalefficiencyasdemandincreases.Furthermore,DC 2standsoutasamoreenvironmentallyfriendlychoicedue toitsemphasisonrenewableenergysources(suchassolar panels)andenergy-efficientHVACsystems.

However, despite being more robust and reliable, DC 1 is more expensive to run, mostly because it uses traditional energyandcoolingsystemsthatmightnotperformaswell asthemoresophisticatedonesinDC2.

5.3 Challenges Faced in Construction

 The intricacies of designing a high-performance data centre with seismic resistance and cuttingedge security features presented scheduling and material availability issues for DC 1. Cost and

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logistical issues were also brought on by the infrastructure needs for the energy efficiency systems(firesafety,powerbackup,andHVAC).

 DC2facedchallengesmanagingthesupplychainfor its modular components, necessitating careful planning to guarantee that every module reached the assembly site on schedule. Adopting liquid immersioncoolingalsopresenteddifficultieswith systemintegrationandguaranteeingthescalability ofcoolingsystems.

Inordertoobtaincertifications,meetlocalsafetystandards, andguaranteeadequatetestingofseismicdesignsandfire suppression systems, both data centres had to overcome regulatoryobstacles.Duringthebuildingstages,therewere additional challenges related to environmental impact assessmentsandenergyregulationcompliance.

5.4 Lessons Learned from Comparison

 AmongthemainlessonsfromDC2istheefficiency and scalability that a modular design provides. Long-term survival depends critically on the capacity to expand as demand increases without interferingwithbusinessprocesses.

 The comparison reveals that advanced cooling systems such as direct-to chip and liquid cooling not only lower running costs but also enhance facility energy performance. Future data centre architecture should take these approaches under consideration in order to lower environmental impact and increase operational effectiveness.

 Both data centres show the need of designing for seismic and environmental safety. Using isolation systems in both data centres guarantees that the buildings can resist natural disasters, so avoiding significantdamagetotheITinfrastructure.

 Space Use: Both data centres clearly showed the needofoptimisingspace.Especially,DC2'suseof modulardesigntomaximiseavailablespacewhile planning for future expansion was a significant learningaboutenhancingoperationalefficiencyand scalability.

6. CONCLUSION

 Designedtosatisfyhigh-performancecriteria,both data centres (DC 1 and DC 2) guarantee dependability, economy, and scalability for contemporaryITsystems.

 For immediate, high-demand operations, DC 1 stands out for its strong structural design, fast constructionschedule,andhigherinitialinvestment inmaterialsandenergysystems;DC2,ontheother hand, offers greater long-term scalability, energy efficiencyvia advancedcoolingtechniques(liquid

immersion),andmodulardesignthatenablesfuture developmentandadaptability.

 Thanks to its sophisticated cooling systems and emphasisonsustainablepracticesincludingenergyefficient HVAC systems and renewable energy integration, DC 2 is more energy-efficient with lowerPUEratios.

 DC 1 is best in offering strong infrastructure and seismicresilience,whichqualifiesforplaceswhere environmentalissueslikeearthquakesareamain worry.

 Bothdatacentresguaranteegreatavailabilityand lowdowntimebyincludingredundancyanduptime characteristics(TierIVclassification).

 DC2'smodulararchitectureandemphasisonspace optimisationprovideinsightfulinformationfornext data centre construction aiming at scalability and flexibility.

 Witheachdatacentreusingdifferentstrategiesto handle supply chain management, integration of advancedsystems,andregulatorycompliance key issues in construction key challenges are addressed.

 Lessonsgainedfromthiscomparisonunderlinethe needofadaptability,sophisticatedcoolingsystems, redundancy, and scalability in the design of contemporary data centres for operations guaranteedforthefuture.

 Considered fundamental for future data centre projects are best practices in fire safety, energy economy,andseismicprotectionseeninbothdata centres.

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