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Caracal Engineering Project

Teraco Data Environments

Task

Teraco Data Environments, an interconnection and data centre platform, is dedicated to powering, protecting, and growing ecosystems that shape Africa’s digital future—sustainably and responsibly.

Teraco is committed to using renewable energy, driving continuous improvement in energy efficiency, and minimising its environmental impact. To unearth this on a bigger scale, they connected with Caracal Engineering for a Solar PV solution that began in its parking lots and reached its rooftops.

Challenges overcome

Teraco required a bespoke solution from top to toe. The rooftop of the data centre was awash with service needs that varied in placement and height. Overcoming them posed significant challenges from structural and constructability perspectives. Our response featured a custom-engineered bespoke design, which we also manufactured and installed.

When designing the structure and system, the team planned for certain challenges; As an example, the possibility that the new system could clash with existing services – such as HVAC units, telecommunication infrastructure, and diesel stores. In addition, we had to engineer a new way of constructing and fixing the structures to the slabs, given a vast number of limitations.

To better navigate the design requirements and ensure accurate information, Caracal Engineering deployed various surveying techniques, including lidar scanning. The lidar scanning painted an extremely detailed image of the roof, with all the limitations identified. We were then able to plan the strut positions for our foundations with far greater accuracy, which meant no on-site fabrication.

Our granular approach illustrated how the benefit of accurate information on the front end translates into greater on-site efficiency.

The system also needed to comply with stringent SHEQ protocols, particularly in terms of safety adherence. During the installation phase, challenges included ill-fitting chillers and condensers, delays in daily work permit issuance, and consistent changes made to health and safety protocols. Our engineers, logistics, and project managers resolved these by:

  • Securing health and safety waivers to enable the timeous receipt of the right permits.
  • Reverse engineering modules on-site to customise the systems to fit the available space, including altering some baseplates to fit on I beams on JB1. We extended the height of stubs to clear pipes on CT2 and moved foundations to clear structures on all of the sites, whilst deploying a significant amount of computing power to the project by using lidar and other surveying techniques for more accurate information. Our robust process is utilised across all our projects.

Constant engagement was conducted with the safety teams to maintain a standard set of rules for all sites.

Results

A bespoke Solar PV system was designed, custom-built, and installed over nine months.

This switched on a significant site of evidence for Teraco from which they could continue to demonstrate their commitment to renewable energy. While it was a time-consuming and somewhat difficult project, we are immensely proud of the work that was undertaken. We underestimated the complexity at the front end, but we were prepared to grind through the challenges and deliver on hard tasks. Notably, the Teraco team was extremely accommodating and tenacious in working with us, and their dedication was a critical part of the success of this Solar PV project.

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