Prefabricated Cold Aisle Modules for Expandable Data Centres
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Solution Overview
Problem
Current data centre construction methods, such as custom-built warehouses and modular data centres, face challenges including high construction costs, long build times, limited flexibility for capacity expansion, and energy inefficiencies due to design constraints and material limitations.
Innovation Solution
A method involving the installation of prefabricated data centre elements, including air handling modules and cold aisle services modules, within an existing or new building, allowing for efficient cooling and flexible layout without requiring extensive on-site construction, using materials like steel, concrete, or wood, and enabling quick assembly with 'plug-and-play' components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by stationary object
If custom-built warehouse style data centres are constructed, then energy efficiency and ergonomic design are improved, but construction cost and construction time increase significantly
Solution Approach 1:
The data centre is divided into modular sections or pods that can be constructed independently and assembled on-site. Each module contains pre-installed IT equipment, cooling systems, and electrical infrastructure, allowing parallel construction of multiple sections to reduce overall build time while maintaining customised energy-efficient designs for each module.
Solution Approach 2:
Critical infrastructure components including cooling systems, electrical wiring, and IT equipment are pre-installed and tested in modular sections before delivery to the final site. This off-site preparation reduces on-site construction time and allows the building shell to be erected quickly, while the pre-assembled modules ensure energy efficiency is built-in from the start.
2Loss of time
If modular data centres using shipping containers are used, then construction time is reduced, but adaptability for capacity expansion and energy efficiency deteriorate
Solution Approach 1:
The data centre is segmented into standardised modular units that can be easily replicated and added to existing facilities. Each module is designed with expandable connections for power, cooling, and data networks, allowing capacity to be increased by simply adding more modules without disrupting existing operations.
Solution Approach 2:
The modular data centre design incorporates dynamic scaling capabilities where modules can be added, removed, or reconfigured based on changing capacity requirements. The standardized interfaces and pre-installed infrastructure enable flexible adaptation to different organisational needs while maintaining quick deployment.
3Use of energy by stationary object
If bespoke data centre designs are created from scratch, then energy efficiency is improved, but construction cost increases
Solution Approach 1:
Standardised modular components are designed to perform multiple functions within each data centre module. For example, integrated ceiling panels provide both structural support and housing for cooling ducts and electrical conduits, while pre-assembled racks combine IT equipment mounting with thermal management features. This multi-functionality reduces the number of separate components needed, lowering material and labour costs while maintaining energy-efficient design.
4Ease of manufacture
If existing buildings are converted to data centres, then construction cost and time are reduced, but adaptability for optimal data centre layout is limited
Solution Approach 1:
Self-contained modular data centre units are designed to fit within existing building spaces while maintaining independent infrastructure for power, cooling, and networking. Each module can be positioned to optimise space utilisation within the existing structure, and multiple modules can be distributed throughout the building to achieve optimal layouts constrained only by the building's physical boundaries rather than requiring complete redesign.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces construction time, lowers costs, enhances energy efficiency, and allows for adaptable data centre expansion, while meeting local building regulations and preferences, thereby addressing the limitations of traditional data centre designs.
Implementation Method 1
air handling module, for providing cooling capacity for the data centre during use
Implementation Method 2
multiple parallel spaced apart cold aisles for entraining and encapsulating the flows of cooling air to the IT equipment in the racks
Data Source
AI summary
A method of making a data centre is disclosed, comprising making a data centre in an existing building (3010) having a floor, walls and a roof, an air inlet and an air outlet. The method includes: installing prefabricated data centre elements by (a) connecting to the inlet an air handling module (3001, 3002); and (b) installing cold aisle services modules (3011) each having one or more integrated blanking portions and one or more data centre services extending along its length terminating with a connection to an adjacent module (3011); and installing racks of IT equipment arranged in parallel rows; the method being so performed that the floor, racks, and cold aisle services modules (3011) together define parallel cold aisles for entraining cooling air flows to the IT equipment. Also disclosed are a data centre, a service carrying frame and a cold aisle services module for a data centre and a supporting frame for supporting prefabricated data centre elements.