I'm sharing with you an article published in the specialized magazine DC Journal:
Building a new data center requires global coordination to ensure all the pieces fit together seamlessly. Bringing it to fruition using traditional construction methods typically takes one to three years from conception to commissioning; however, manufacturing and installing a modular data center can have an organization up and running in just a few months.
This accelerated timeline demands seamless management between the production of modular components at the factory and the site where the data center will be located. It also requires the oversight of a project manager with expertise in both traditional and modular construction methods, and the leadership skills to motivate and effectively manage multiple teams working simultaneously.
Managing the fabrication, outfitting, and preparation of a modular data center while simultaneously overseeing site work, excavation, foundation placement, and utility installation at the final location requires specialized skills and knowledge. A project manager must be well-versed in logistics, supply chain management, and parallel workflow, and must demonstrate a high level of leadership, organization, and accountability.
Most importantly, a project manager of this type must be fully committed to meeting the needs of the owners before, during, and after the completion of the data center.
Personalization From the Start
Under ideal conditions, facility owners involve a data center provider and modular project manager early in the planning and design process. This helps avoid design and implementation errors and omissions that could lead to delays, cost overruns, or other unnecessary problems later on.
With modular data centers, each design is as unique as the owner builds it. This customization, which isn't available with containerized modules, is a significant departure from facilities built using traditional construction methods. With traditional construction projects, the overall building design limits the design of the data center within. Construction specifications—such as ceiling height, floor construction, power, air conditioning, and the placement of load-bearing walls—drive and sometimes restrict the data center's design.
Finalizing all final drawings and specifications is the first task in constructing a new modular data center once the owner gives the green light to proceed. These final drawings will guide and direct the design and development of the custom modular components. The project manager must be an integral part of this process so that expectations, priorities, and requirements are well understood by everyone involved. Furthermore, the project manager should identify any cost-saving opportunities for the owner and schedule them through various design, installation, or equipment changes.
Bringing concepts back to reality
Typically, completing all the drawings takes about eight weeks from the start of the design work. The beginning of subassembly manufacturing around the ninth week of the project marks the next phase of modular data center development.
Over the next month, the project manager will coordinate the fabrication and assembly of structural steel frames, wall panels, and support structures, which come together to form the data center. They will also manage the start of groundwork at the final data center location to prepare for the arrival of the modules.
The project manager's primary focus during this time should be ensuring that all components manufactured and equipment delivered are consistent with the manufacturing drawings. They should also provide regular updates to the owner, as well as a two-week calendar outlook (a four- and six-week outlook should also be readily available), and keep the owner informed of cost projections for any owner-directed change orders.
As work enters week 12, the major systems and subassemblies arrive at the plant, and factory assembly begins. On-site, sewage, water, power, and other infrastructure components are put in place and prepared for the arrival of the modular units in a few weeks. Overall, the data center construction is approximately 401,300 tons complete at this point, whereas a comparable project built using traditional methods would only be around 101,300 to 151,300 tons complete in three to four months.
Throughout this period, an effective project manager will keep the owner informed about progress and the status of the schedule while ensuring that all the pieces come together at the right time.
A new modular data center is fully built and assembled at the factory before being shipped. This approach allows for rapid deployment in the field upon delivery, ensuring accurate and efficient assembly. After assembly is complete, typically 17 to 18 weeks after the project begins, system testing commences with the project manager overseeing all activities and confirming that all components meet specifications. Since the modular data center is built in a controlled, weather-protected environment, quality and efficiency are maximized while traditional delays are minimized.
The project manager must also have a fully coordinated plan for delivery, placement, and decommissioning in place at this time. This coordination is critical to minimizing the impact of the work on the owners, other subcontractors, and ongoing operations. On-site, all preparation work will be approximately 901 to 951 TP3T completed, whereas at the same point in the traditional construction lifecycle, the work would only be approximately 201 to 301 TP3T done, weather permitting.
Bringing It All Together
The new data center is disassembled into several sections for shipment after factory testing is complete. But before the components leave the factory, a skilled project manager will prepare all members of the site installation team for the final assembly. In addition, the project manager must obtain written confirmation that all on-site work is complete and that the site is ready to receive the modules.
In week 19, less than five months after the project began, the factory is ready to ship the new data center. The modules are shipped by truck, and the delivery is choreographed so that the various pieces arrive at the final location in the order in which they will be installed.
Due to extensive coordination before and during shipment, the installation of a complete data center at the site could be completed in as little as two to three days, depending on its size. During this period, the project manager should provide ongoing updates to assist the owners in coordinating utility connections and other site tasks.
Once all systems are rechecked to confirm no damage occurred during shipping, the new data center is ready for IT installation. Normally, the facility owner is responsible for this installation, but with a modular data center, racks will already be positioned and installed, power will be installed and labeled, and cooling will be operational.
Around 25 to 26 weeks after the project begins, when a traditional construction project is only starting interior construction and is approximately 301 to 401 to 3 ...
Any improvements to the on-site assembly schedule should be communicated at the earliest possible opportunity to allow all parties to take advantage of one of the biggest benefits – a drastically reduced modular deployment construction schedule and earlier billing dates.
For an exceptional project manager, the construction, installation, and commissioning of a facility is just the beginning of the relationship with the owner. An exceptional project manager will remain just a phone call away and will still be committed to providing support until the next customized solution is needed.
Note: Article extracted from Data Center Journal, written by Stephen C. Madaffari