Data Centers play a critical role in modern digital infrastructure. They support the rapid expansion of cloud computing, AI technologies, and global data storage needs. Consequently, the structural design of Data Centers must accommodate highly specific technical and operational requirements. The structural system of a Data Center must align with the technical complexity of the equipment housed within and the need for unwavering operational reliability. Layouts must support efficient airflow, cable management, and mechanical integration, all while maintaining high structural performance and durability.
Cost efficiency and rapid project delivery have also become paramount in today’s competitive market. Investors and operators demand fast completion to bring new facilities online quickly. As a result, selecting the appropriate structural system is critical to project success, influencing both the construction timeline and long-term operational effectiveness.
This article explores the structural systems commonly used in modern data center construction and outlines key design considerations drawn from gbc engineers’ experience across Europe and Southeast Asia.
Structural Requirements of a Data Center
Data Centers impose distinct structural demands that set them apart from conventional commercial buildings. One of the most significant challenges is supporting the heavy loads from critical infrastructure components, including:
- Server racks with extremely high point loads
- Backup power systems (generators and UPS units)
- Large cooling installations such as chillers, cooling towers, and HVAC equipment
- Distribution systems like chimneys, large ducts, cable trays, and pipe networks
- Electrical and fire suppression systems (batteries, transformers, sprinkler tanks, etc.)
Beyond vertical loads, these facilities often require medium to large span configurations to create open, unobstructed layouts. Such layouts facilitate future modifications and allow efficient integration of mechanical and electrical systems within the data center architecture. The structure must also offer high flexibility to enable internal reconfigurations, equipment upgrades, or load redistributions over the facility’s service life.
Another key consideration is construction speed. Owners and developers want to bring new data centers online as fast as possible to meet demand and start generating returns. Therefore, structural systems that minimize on-site labor and enable parallel off-site prefabrication are usually preferred, as they help optimize the use of available resources and improve project delivery timelines.
Considering heavy equipment loads, large spans, flexibility, and the need for rapid construction, prefabricated structural systems, especially those based on precast concrete technology, have emerged as a highly favorable solution. They provide excellent structural performance, consistent quality, and significantly reduced on-site construction times. This makes them ideally suited for modern data center developments. Prefabrication not only accelerates the schedule and improves speed-to-market, but also enhances cost control and quality, offering key benefits for stakeholders.
Read More: What Are the Real Challenges to Design a Data Center? - gbc engineers
Typical structural solutions
Slab system
The choice of floor slab system is a critical factor in Data Center design, as it influences structural capacity, construction speed, flexibility, and cost. Below, we outline four common slab types frequently considered in modern Data Center projects, along with their pros and cons:
Cast in situ slab
In this approach, a fully reinforced concrete slab is poured and cured on-site using traditional formwork.
Pros:
- High flexibility in design and detailing
- Excellent monolithic behavior (continuity and stiffness)
- Easy to integrate with complex geometries or local thickening
Cons:
- Long construction time due to on-site curing
- High labor intensity and formwork requirement
- Weather-dependent quality control
Filigree slab
This is a hybrid system where a thin precast concrete slab with bottom reinforcement is placed on-site and then completed with an in-situ concrete topping.
Pros:
- Faster than cast-in-situ due to reduced formwork
- Good surface quality from factory production
- Integrated reinforcement simplifies on-site work
Cons:
- Still requires on-site concreting and curing
- Joint detailing is critical for performance
- Moderate construction speed improvement
Hollow slab
These slabs are precast, prestressed concrete elements with internal voids that reduce weight while maintaining structural strength.
Pros:
- Fast installation and reduced construction time
- Lightweight with good span efficiency
- Factory-controlled quality
Cons:
- Limited flexibility in opening placement (e.g., for MEP services)
- Requires careful detailing for connections and fire resistance
- Not ideal for heavily concentrated loads unless specially reinforced
TT slab (pi slab)
Precast concrete slabs shaped like double T-beams (“TT” shape) are often used for structures requiring large spans and heavy load capacity.
Pros:
- High load-bearing capacity for large spans
- Excellent for repetitive, modular layouts
- Reduces need for secondary beams
Cons:
- Heavy elements require large lifting equipment
- Transportation and handling limitations
- Integrating openings for MEP services may require additional work or coordination
Read More: Why Modern Data Centers Need Smart Architectural Design - gbc engineers
Beams
Selecting an appropriate beam system in a Data Center depends on several key factors, including the expected load intensity, span length, floor-to-floor height constraints, and required construction speed. Beam systems play a crucial role by supporting floor loads and transferring them to the vertical structural elements (columns or walls). For large spans or high-load areas, prestressed or full-depth precast beams are often preferred, as they minimize deflection, use material efficiently, and can accelerate construction. Conversely, where structural flexibility or integration with building services is a priority, semi-prefabricated (composite) or cast-in-situ beams may be more suitable. Ultimately, the beam solution should align with the overall structural strategy, balancing performance, constructability, and coordination with MEP (Mechanical, Electrical, and Plumbing) systems.
Columns
In Data Centers, columns are predominantly prefabricated elements, offering significant advantages in construction speed, precision, and quality control. The choice of column type depends on the project’s structural requirements, the architectural layout, and client preferences. Two main column configurations are commonly used:
Pendular Columns (Slab-to-Slab Columns):
These columns span from one floor slab up to the next floor slab. Beams rest directly on top of each pendular column at every level. This system simplifies the erection sequence and allows flexibility in beam placement, but it requires careful detailing and secure connections at each floor level to ensure structural continuity between stories.
Multi-Story Columns with Corbels:
In this configuration, columns extend through multiple floor levels, and beams are supported on integrated corbels cast as part of the column elements. This method reduces the number of joints between floors and improves vertical load transfer. It typically requires a mechanical column-base connection (for example, a Peikko column shoe) at the footing to ensure stability and to facilitate easy assembly during construction.
When choosing between these two column approaches, engineers must consider factors such as the story height, load path continuity, the planned erection sequence, and the level of coordination needed with the precast fabricator. Each project may favor a different solution based on these parameters to achieve the best results in terms of structural performance and construction speed.
Read More: How to Achieve Tier 4 Data Center Certification - gbc engineers
Wall system
Structural walls in Data Centers serve both load-bearing and enclosure functions. They must support heavy vertical loads, provide lateral stability against wind or seismic forces, integrate with MEP systems, and often meet strict fire-resistance and thermal insulation requirements. The choice of wall type can significantly affect construction speed, design flexibility, and how well the walls coordinate with other building systems. The most common wall systems include:
Cast in situ wall
Concrete walls that are fully formed, reinforced, and poured on site.
Pros:
- High flexibility in wall layout and detailing (walls can be shaped or adjusted on-site as needed)
- Excellent monolithic behavior and stiffness (a single continuous structure)
- Easier to accommodate complex connections with slabs or penetrations for services during construction
Cons:
- Labor-intensive and time-consuming construction process
- Quality and curing are dependent on site conditions and weather
- Requires extensive formwork setup and significant curing time before full loads can be applied
Hollow wall
A hollow wall is a semi-precast system consisting of two thin precast concrete faces (often called wythes) that are connected by steel trusses or lattice girders. The cavity between these precast layers is then filled with concrete on-site, forming a solid structural wall once the concrete cures.
Pros:
- Faster to construct than a fully cast-in-situ wall, while providing a better surface quality from the factory- produced elements
- Combines the accuracy and quality of precast production with the monolithic solidity of an in-situ concrete infill
- Can offer good thermal and acoustic performance, especially if insulation is installed between the precast layers
Cons:
- Still requires on-site concreting to fill the wall, so it does not eliminate wet work entirely
- Precast wall panels can be bulky, making transportation and handling more difficult
- Joints between panels and the continuity of reinforcement must be carefully designed and executed for structural integrity
Full precast wall
A full precast wall is fabricated entirely in the factory as a large concrete panel, which is then transported to the site for assembly with no additional casting required on-site.
Pros:
- Very fast installation on-site, dramatically reducing construction time
- High-quality finish thanks to the controlled factory production environment
- Requires minimal on-site labor, improving safety and reducing on-site staffing needs
Cons:
- Limited design flexibility for openings and embedded elements
- Transportation and lifting constraints
- Higher need for accurate coordination during design phase
Read More: What Are the Main Components of a Software-Defined Data Center? - gbc engineers
Foundation
As with any building, Data Center foundation design is primarily governed by the site’s geotechnical conditions. Projects built on weak or highly compressible soils typically require deep foundations (such as driven piles or drilled piers) to achieve adequate load-bearing capacity and to control settlement. Conversely, sites with strong, stable soil may allow for shallow foundations, such as spread footings or a raft slab, depending on the column layout and overall load distribution.
For moderate column loads, an efficient technique is to cast the column base and its footing as a single monolithic element. Doing so reduces construction time and simplifies alignment on site. This integrated approach is especially advantageous when using prefabricated columns, as it ensures accurate positioning and anchorage of the columns during installation.
Ready to Future-Proof Your Data Center?
Partner with gbc engineers to design a facility that delivers performance, reliability, and long-term value.
🌐 Visit: www.gbc-engineers.com
🏗️ Explore Our Services: Services - gbc engineers
Conclusion
The structural design of Data Centers demands careful consideration of a wide range of technical, logistical, and operational requirements. High structural loads, large open spans, flexibility for future expansion, and fast construction timelines (speed-to-market) are among the most critical factors influencing design decisions for these projects.
This document outlined various slab, wall, and column systems commonly used in Data Center construction, highlighting their respective advantages, limitations, and suitable applications. It emphasized that structural system selection must be based on project-specific criteria – including building geometry, load conditions, transport and lifting constraints, MEP integration needs, and architectural goals – rather than a one-size-fits-all approach.
In many cases, a mixed or hybrid structural approach offers the best balance between performance, cost, and construction efficiency. Prefabricated and semi-prefabricated systems in particular are very well- suited for modern Data Centers, offering faster deployment, enhanced quality control, and reduced on-site labor — key advantages in today’s competitive market for developers and operators.
Ultimately, the choice of structural system should be made by qualified structural engineers in close collaboration with architects, MEP designers, and precast manufacturers. A well-coordinated, project- specific structural concept is essential for delivering a high-performance, cost-effective, and future-ready Data Center facility.