The construction of the Rabale Data Centre in Mumbai stands as a testament to the power of innovation and meticulous planning in overcoming significant constraints. Situated on a tight urban plot with limited clearance and executed during the challenging backdrop of the COVID-19 pandemic, this state-of-the-art facility exemplifies modern engineering and sustainable design. Combining Pre-Engineered Building (PEB) technology with advanced RCC integration, the project harmonised structural precision, aesthetic appeal, and environmental stewardship to deliver a high-performance data centre equipped to meet the rigorous demands of the digital age.
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The construction of the Rabale Data Centre in Mumbai presented a unique challenge due to the restricted plot size, which required meticulous planning of utilities, sequencing of construction activities, and coordination among multiple agencies working on-site. Close collaboration and strategic planning were imperative to the project’s success.
The project scope encompassed detailed engineering, manufacturing, supply, and erection of structures using Pre-Engineered Building (PEB) technology, executed by Interarch Building Products Limited.
The engineering teams from Structwel and Interarch designed the data centre in compliance with the IS-800-2007 code for steel structures. The structural design accounted for complex requirements, as the facility houses Battery Rooms, Equipment, Server Rooms, Chiller Platforms, DG Sets, and Thermal Storage Tank Loads. To address these challenges, the building was engineered to withstand a temperature gradient of 10o C. Design tools such as Staad.Pro Connect Edition and 3D modeling were employed for the analysis and design of the steel members used in the structure.
The execution of the project coincided with the COVID-19 pandemic, adding another layer of complexity. Adhering to COVID-19 protocols required careful planning and execution. However, the combined efforts and seamless teamwork of Structwel and Interarch ensured the building was handed over to the stakeholders within the stipulated timelines.
Smart Design
The design and analysis of the structure were relatively straightforward, typical of a standard multi-storeyed building. However, the connection detailing and integration with the façade and dry walls required significant attention. While not particularly challenging, these aspects demanded careful consideration to ensure the building’s long-term serviceability, especially with respect to age-related deterioration and environmental impact, including effective leak-proofing.
Key design features of the structure include:
– Design Standards: The building was designed following Indian codes, with a Response Spectrum Analysis performed in accordance with IS 1893: Part-4-2015.
– Structural Configuration: The structure is a G+7 flat roof building, standing 36.5 meters tall, constructed using a combination of steel and RCC.
– Floor Design: The floors feature deck slabs and grating, with heavy load capacities ranging from 15 kN/m² to 20 kN/m².
– Structural Integration: Each floor includes a junction with an RCC structure. A special engineering solution was implemented for the steel structure supported on the RCC structure, utilising insert plates for seamless integration.
– Architectural Elements: The structure’s periphery includes a combination of brick walls, glazing, ACP, and other architectural features to enhance aesthetics. Structural arrangements were meticulously designed to ensure the building remained leak-proof.
– Drainage System: A proper drainage system was designed for the flat roof to prevent water accumulation.
This design approach ensured a robust and durable building, addressing both structural integrity and aesthetic appeal while accommodating environmental considerations.
Tight Spaces
The project site presented significant challenges due to limited space, with only 5 m of clearance on both the left and right sides of the building. To address these constraints, the project management team from Interarch employed a 130 ft boom lift for the erection process. Additionally, the site’s roadside location meant that no on-premises material stacking areas were available, as per the client’s provisions.
To manage this, material storage was arranged half a kilometer away from the site, requiring meticulous coordination to organise and transport materials as needed. The majority of the erection work coincided with the monsoon season, necessitating the implementation of stringent safety measures, well-planned erection methodologies, and effective on-site material management to ensure smooth execution despite the adverse conditions.
Flexibility in Action
The project posed significant challenges, not in terms of design but in managing the timelines for integrating different structural systems. The staircase and lift blocks were designed in RCC, while the remaining structure utilised steel. Although designing insert plates at the planning stage was straightforward, complications arose during execution due to the vastly faster erection timeline of the steel structure compared to the RCC blocks.
As a result, the insert plates were not ready when the steel erection reached certain levels. This issue was further compounded by the lack of space on the plot, which slowed the erection process due to delays caused by the RCC block construction. Ultimately, mid-project design modifications were required, involving the installation of temporary steel members within RCC columns and shear walls to support the insert plates. This adjustment allowed the PEB erection to proceed independently from RCC construction activities.
For the external façade, 2-hour fire-rated drywall panels were employed, complemented by ACP and glazing for the office block façade. The detailing of this system with the PEB structure was particularly challenging, requiring precise planning to ensure the building remained leakproof.
Engineering Strength
The slab design for the data center utilised a composite system comprising deck sheets and an RCC slab on top. This approach was carefully engineered to support the heavy loads typical of data centers while meeting enhanced codal requirements for earthquake resistance and fire safety. The design focused on the optimal spacing of secondary steel members to ensure the deck sheets and concrete slab could withstand these substantial loadings effectively.
The terraces, heavily loaded with MEP (Mechanical, Electrical, and Plumbing) services, presented a unique challenge due to their limited available space. To address waterproofing concerns, chemical waterproofing was applied over conventional systems to maintain adequate slopes and ensure zero leakages.
A key issue was planning the layout of MEP services to avoid obstructing the natural flow of water along the roof slopes. Stagnation caused by blocked water paths leading to down-take pipes often results in leakages. By strategically organising the MEP services, the team ensured efficient water drainage and minimised the risk of water-related issues.
Adapting to Challenges
The steel design for the project was undertaken during the tail end of the COVID-19 pandemic, a period when most industries had adapted to new ways of working. Remote work and video conferencing had become the norm, and both the Interarch and Structwel design teams managed to work seamlessly within these constraints, ensuring that the project timelines remained unaffected.
A significant challenge for this project was the lack of space, with only the mandatory marginal open spaces available around the building. This spatial constraint necessitated several on-the-spot adjustments, such as the inclusion of steel members to support insert plates, as previously described. This modification was a crucial adjustment made to expedite the project without compromising its structural integrity.
Additionally, the restricted space meant that erection cranes and boom lifts often had to operate from the roadside, as they couldn’t achieve the required angles within the plot. The primary decision to opt for a steel structure over a conventional RCC structure was driven by the need for faster construction. To leverage this advantage, several innovative, on-site solutions, or engineered ‘jugaads,’ were implemented to facilitate and accelerate the erection process. These adaptations were pivotal in overcoming the logistical and structural challenges posed by the constrained site.
Sustainable by Design
The data centre project adhered to all green building norms typically followed for sustainable construction. Safety and sustainability remained central to the project’s focus, with the building designed to achieve a zero-carbon footprint and deliver high environmental performance.
One of the notable features of the data centre is its energy-efficient ventilation system. The unique building design facilitates proper airflow and temperature control, creating a healthy and comfortable indoor environment. Additionally, the project incorporated methods to reduce the overall carbon footprint by minimising solid waste, improving air and water quality, and conserving natural resources by lowering consumption rates.
Sustainability measures extended to the production process, where energy-efficient methods were employed at Interarch’s state-of-the-art manufacturing facilities. These methods significantly reduced greenhouse gas emissions. Furthermore, efficient skylights were installed on the roof and wall areas to reduce dependency on artificial lighting, thereby saving electricity. The use of roof and wall sheets with a high Solar Reflectance Index (SRI) also contributed to energy efficiency.
To maintain indoor air quality, Low VOC (volatile organic compound) paints were utilised, which simultaneously minimised heat transfer. Rainwater collection was ensured through the installation of gutters and downtake pipes on each building, supporting proper drainage. The roof structure was also designed to accommodate solar panels, enhancing energy efficiency.
Interarch employed the TRACDEK SS2000 standing seam roof profile to provide a leak-proof solution, further reinforcing the building’s durability and sustainability. These initiatives collectively demonstrate the project’s commitment to environmental stewardship and sustainable design principles.
Quote
“The project faced significant challenges due to limited space and the need for precise coordination between multiple agencies. While the structural design was standard for a multi-storey building, the real challenge lay in managing the timelines for integrating steel and RCC systems. The fast-paced erection of the steel structure required mid-project adjustments, such as adding temporary steel members to support insert plates. We also focused heavily on sustainability, incorporating green building norms, efficient ventilation, and energy-saving features like solar panel support, while ensuring the building’s long-term durability and leak-proof integrity.”
– Kaustubh Raikar, Executive Director, Structwel Designers & Consultants Pvt Ltd
“The Rabale data centre project showcased Interarch’s ability to deliver excellence under challenging conditions. Despite site constraints and challenging environmental factors like monsoons and COVID-19, we ensured on-time delivery through meticulous planning and strict adherence to safety and quality protocols. Rigorous inspections, advanced testing methods, and innovative approaches helped maintain structural integrity and exceptional standards. It was a rewarding experience that highlighted our commitment to precision, teamwork, and client satisfaction while reinforcing our expertise in executing complex projects successfully.”
– Manish Garg, CEO, Interarch Building Products Ltd
Fact File
Project: Data Centre, Navi Mumbai
Architect, Structural Consultant, Project Management: Structwel Designers & Consultant Pvt Ltd
Steel Contractor, Supplier: Interarch Building Products Ltd
Tonnage: 1,304 MT
Status: Completed
