Grooved mechanical pipe joining, combined with virtual design, prefabrication and BIM, holds exciting potential to overcome the challenges of data centre construction and sustainability in the Middle East, says Zeyd Ammoura, Division Manager for Middle East, Africa and Turkey at Victaulic.
The Middle East data centre market is expanding at an unprecedented pace, projected to grow from US$12.3 billion in 2024 to US$28.2 billion by 2029. But this growth doesn’t come without its challenges, for instance, construction. While the piping systems for cooling and fire protection may not be the first consideration, they play a significant role in overall project success.
Given that large-scale data centres often require kilometres of piping, the choice of pipe joining method, along with the use of virtual design, prefabrication and BIM, can significantly impact project schedules, quality, carbon footprint and the facility’s adaptability to future needs.
Simple, mechanical pipe joining
The grooved mechanical pipe joining method has existed for over a century but is becoming increasingly popular as an easier and emission-free alternative to welding that can help overcome many of the challenges faced on large-scale data centre construction projects in the Middle East.
In this method, pipes are cut to length, grooved and then connected using a mechanical coupling, secured by two bolts. These joints are as reliable as traditional welds, and the couplings can be easily removed for maintenance, system expansion, or reconfiguration without causing any damage. At the end of the system’s life, the couplings can be repurposed or recycled, supporting a circular economy. These couplings are already made from 98% recycled content and are produced using methods that reduce emissions by 80% compared to traditional furnaces.
Furthermore, the installation is straightforward so anyone can be quickly trained to install the couplings – which can speed up the process by up to 5x compared to welding and help overcome the challenge of skilled labour shortages. Throughout a large-scale data centre project, which may require thousands of joints, these time savings can translate into significant gains.
Another benefit is that, unlike welding, this method generates no heat, emissions, or waste during installation, making it a more comfortable option for workers in hot climates while also reducing health, safety, and fire risks, as well as the overall environmental impact.
Early supplier engagement
The grooved mechanical pipe joining method offers a range of benefits, but these advantages can be amplified by engaging suppliers early in the project. Early collaboration enables project teams to tap into specialised expertise that allows for the integration of advanced techniques, including virtual design, prefabrication and Building Information Modelling (BIM) to streamline the entire construction process of cooling and fire protection systems.
Accurate virtual 3D models
Virtual design is a powerful strategy that allows all stakeholders to visualise the piping system layout, optimise space usage and ensure long-term effectiveness and efficiency. When it comes to installation, in particular, the process is much smoother as precise modelling mitigates the risk of waste and costly, on-site modifications that can be common in complex data centre environments. Any potential clashes or issues are addressed long before construction begins.
By designing virtually in 3D, the entire project team can also better understand how grooved mechanical pipe joining compares to traditional welded systems in terms of time, material and cost savings.
To ensure the accuracy of models, Victaulic Tools for Revit is a free-to-download resource that provides engineers with access to a library of digitised grooved mechanical pipes, couplings, valves and fixtures. However, for those who prefer an end-to-end solution, Victaulic also offers Virtual Design & Construction (VDC) services, providing customers with fully engineered, coordinated virtual models that ensure seamless installation.
Prefabrication of piping spools
While virtual design is not a requirement for prefabrication, it is a key enabler of this additional strategy for optimising data centre piping systems. Prefabrication involves assembling sections of piping (known as spools), complete with fittings and valves, in an off-site facility – whether by Victaulic or a contractor’s own fabrication shop.
As well as reducing on-site labour requirements and accelerating installation, prefabrication significantly reduces waste. Through controlled manufacturing processes, material usage is optimised, minimising excess pipe lengths and scrap materials commonly found on construction sites.
The precision of prefabricated components also ensures fewer errors during installation, which further cuts down on waste and the need for rework. Furthermore, prefabrication facilitates the coordination and consolidation of deliveries, reducing transportation complexity, costs and emissions. These efficiencies not only drive cost savings but also align with the growing demand for sustainable construction practices in the Middle East.
Real-time status updates
Updating the status of prefabricated components in BIM gives all stakeholders full visibility and control over project progress. The Victaulic SpoolTracker app for iOS and Android simplifies this process further by tracking components even after they leave the fabrication shop.
Using QR codes, SpoolTracker offers instant visibility into the location and status of pipe spools. It helps users quickly identify issues, adjust components before fabrication, prevent lost deliveries, allocate labour efficiently and ensure accurate installation. These features support faster, more precise project completion, while minimising unexpected costs. With its intuitive interface, SpoolTracker integrates easily into daily routines, even working offline to ensure seamless updates when back online. This guarantees that project data stays current and accurate, regardless of site conditions.
A collaborative approach for the future
For data centre operators in the Middle East, the path to success lies in early collaboration with innovative solution providers to implement modern project management strategies that deliver efficiency and sustainability not only during construction but also throughout the life of their facilities.
Victaulic is proud to be a partner to data centre operators in the Middle East, offering comprehensive, one-stop solutions that address the unique challenges of the region – and as the demand for data centres continues to grow, our commitment to innovation, the environment and long-term performance will help ensure that these facilities operate efficiently, safely and sustainably for years to come.
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