Today, data centers are firmly at the heart of our digital lives, underpinning everything from businesses and hospitals to government agencies. As a result, protecting the vital IT equipment housed inside these buildings is paramount – and that starts outside of the facility.

Come rain or shine, data centers must be equipped to operate uninterrupted, regardless of external conditions. Ensuring wind and rain-resistance for cable trays, building penetrations, and roofs is central to maintaining uptime.

Roof and wall penetrations – such as those for HVAC equipment, rooflights, and roof access hatches – are essential for facilitating data center functionality. But they represent potential weak spots for water ingress, and therefore demand careful planning and an expert weatherproofing strategy that utilizes modern weatherproofing techniques.

Against this backdrop, in a recent DCD>Broadcast, Steve Jones, joint managing director of Jones Weatherproofing, shares why traditional weatherproofing techniques for vertical penetrations are often insufficient, and how a bespoke solution can provide the robust detailing these critical facilities require.

You can’t go around it, you have to go through it

Vertical penetrations are holes where pipes, ducts, cable trays and other equipment can enter or exit the building. In data centers, these openings are typically used to optimize space, improve cooling efficiency, and manage complex infrastructure – especially in dense, urban environments.

“Inside data centers, space is at a premium,” explains Jones. “There's so much critical equipment, ducting, cabling, and complex connectivity points that demand direct access outdoors, right into external plants. The easiest and fastest route out is through the walls of the building.”

These penetrations are essential for effective operations. They deliver routes via which power can reach the right equipment, efficient heat removal can be carried out, and networks can be connected to devices across different levels of the building.

But cutting holes in facility walls inevitably brings about some challenges, as Jones explains: “What we see happening is that when these buildings are being designed, the location of penetrations are put on the drawings, the equipment is fitted through, and the hole that’s been created is then left on the back burner to be dealt with at the last minute.”

With data centers emerging at scale across the globe in traditional strongholds and key developing markets – facilities must be prepared to weather any storm, in any climate.

To make matters more complex, the number and size of penetrations that facilities require is on the rise as a result of increasingly complex, high-density workloads driving up the amount and weight of the equipment required to support modern operations.

Out with the old

“Robust weatherproofing is fundamentally about reducing risk to plant and equipment,” states Jones. “Creating a completely dry environment internally and preventing water ingress are foundational criteria for critical digital infrastructure.”

With data center capacity skyrocketing, IT equipment is not only larger in size and volume, but more valuable – both in terms of actual cost and the level at which it is relied upon.

In today’s high-stakes landscape, traditional weatherproofing methods no longer meet the mark. The risk-factor for equipment being damaged or failing, and facilities being forced to shut down due to water ingress, is higher than ever.

“The traditional approach involves fitting plates that have been prefabricated off site, cut and crossed over one another, mechanically fixed in place, and then sealed with a mastic,” explains Jones. “The problem is that over time – around four to five years – the mastic seal can dry out and shrink, allowing water to penetrate the joint itself.

“Not only that, but due to the way in which it’s been cut, the plating can develop rust at the joints, leading to pitting on the original plating, which can then cause damage to the walls of the building itself.”

To eliminate that risk altogether, Jones Weatherproofing offers a completely seamless, bespoke weatherproofing solution. Its vertical penetration weathering system is fixed and bonded directly to the panel, creating a solid, highly-durable seal.

Data centers come in all shapes and sizes, in a range of different locations, with varied detailing – meaning there’s no one-size-fits all solution. Outdated methods that attempt to tack-on panels with sealants unfit for purpose and longevity, fail to respond to the diverse architectures and finishes that characterize modern facilities.

“A lot of data centers we've worked on actually have curved cladding,” adds Jones. “That kind of exterior finish makes it impossible to fit a flat plate in the traditional way and maintain proper weatherproofing.”

Aesthetically, a seamless solution also delivers a clean, tidy finish – harmonizing form and function. “We can match any color and adapt to any shape, all with a 25-year warranty on whatever we apply,” says Jones.

Be prepared for anything

As Jones highlights from the start, one of the central pitfalls when it comes to traditional weatherproofing approaches is a lack of proper planning for how to deal with penetrations once they’ve been made.

That’s why weatherproofing must be a priority right from the design stage. A professional team can assess building plans, drawings, mock-ups or images, alongside unique customer requirements, to develop an effective weatherproofing strategy well in advance of the openings being made.

“It's crucial that we also discuss access to the openings early on, because of the sheer number of penetrations we’re seeing in data centers today,” explains Jones. “If it’s left too little too late, creating the necessary access to the areas that require weatherproofing can become an expensive process.”

Even the most well-conceived plans can veer off course and take on a different shape thanks to unforeseen hurdles. As such, the ability to pivot on site and adapt to changing circumstances is an essential tool when it comes to any construction project.

“There've been numerous instances where we’ve arrived on site and we’re faced with something quite different than what was specified on paper,” says Jones. “So we’re very adaptable.

“We can make suitable flashings on the day, on location, with the equipment we have available. We’ve also seen some instances where the plants end up generating a lot of movement, and so we can create a dual flashing top weatherproofing that accommodates shifts and vibrations.”

Those contingencies ensure that work can be carried out and timelines can be met, even when plans change and projects are forced to pivot. In today’s fast-paced, highly competitive landscape where facilities race to become operational – that foresight and adaptability is a crucial advantage.

Jones adds that even when customers have enlisted the company after they’ve completed a build and realized they require a new penetration for an access point that was missed in the initial plans – the flexibility of the Jones Weatherproofing system means it can be retrofitted with little disturbance to the finished building.

“Best practice is without a doubt to make inquiries early on,” he reiterates. “Because of our experience, the sooner we get information on a project, we can often nip a lot of problems in the bud from the outset.”

Driving innovation

A perfect storm of complexity exists as a result of unpredictable weather conditions, increasing pressure on facilities to operate uninterrupted, the value of today’s IT equipment, and the growing number of penetrations required to support the volume of equipment necessary for modern operations.

Strategizing right from the design stage, plus a modern, customized approach that can adapt to the unique requirements of the individual site, building, and precise penetrations – are key ingredients for delivering effective weatherproofing and protecting what lies inside the data center.

With 45 years of experience in weatherproofing and 15 in the data center sector, Jones Weatherproofing isn’t sitting back to ride the wave of innovation – it’s firmly in the driving seat. Jones concludes:

“We've never sat back and thought, yes, this is okay. We're always trying to be innovative, move forward, and keep developing. We have to move with the times and make sure that we're keeping up with our customer’s requirements.”

To hear more about how Jones Weatherproofing is working to deliver watertight data centers efficiently and reliably, watch the full DCD>Broadcast episode, here.