Secure Prefab Control Rooms for Critical InfrastructureClimate-Controlled, Blast-Resistant, IEC-Compliant

A prefab control room is a factory-manufactured structural enclosure designed specifically for housing DCS, SCADA, relay, or communications equipment in industrial environments. Unlike site-built control rooms that are assembled from individual materials on site (risking quality variability, schedule overruns, and performance gaps), a prefab control room arrives factory-tested and ready for service connection. Environmental performance — temperature, humidity, positive pressure, EMC shielding — is verified in the factory before the unit ships.

Our standard blast-resistant range covers reflected peak pressures of 0.5–3.0 psi (3.4–20.7 kPa), which covers most onshore process plant applications. For higher blast loads — LNG terminal blast scenarios, explosive risk zones — we design to the specific blast load specified by the client's loss prevention engineer. Blast calculations are performed to ASCE 7 Chapter 2 and ISO 17776 methodologies.

DCS and SCADA equipment typically requires 20–25°C and 40–60% RH (non-condensing). We specify precision air conditioning systems — not standard split units — with N+1 redundancy (two units each sized at 100% load), positive pressure relative to the external atmosphere, and BMS monitoring. For corrosive or dusty atmospheres, HEPA pre-filtration is added.

A raised access floor creates a plenum void — typically 300–600mm — beneath the operational floor. This void carries all cable trays, data cables, power cables, and HVAC supply air to equipment positions. It allows cables to be run, modified, or replaced without opening the ceiling or walls. The anti-static floor finish (IEC 61340 compliant) prevents electrostatic discharge damage to sensitive electronics.

IS 50244 is the Indian Standard for requirements of control rooms in HV switchyards and substations. It specifies structural fire resistance, cable entry sealing, ventilation and HVAC, lighting levels, cable management, and access provisions for substation control buildings. Poojary Prefab's substation control rooms are designed in full compliance with IS 50244 requirements — providing CEIG-compliant documentation for state electricity board and transmission utility approvals.

Yes. For applications where external electromagnetic interference must be excluded — or where emissions from internal equipment must be contained — we design EMC-shielded enclosures with continuous galvanised steel skin bonding, shielded cable entry provisions, and RF-gasketed door sets. Shielding effectiveness is specified per IEC 61000-5-7 or to the client's EMC budget analysis.

Cable entries in blast-resistant control rooms are a critical design detail — every penetration is a potential blast pressure path. We use blast-rated MCT (multi-cable transit) frames that maintain the blast envelope integrity while providing the required cable segregation and fire stopping. The number, size, and blast rating of all cable transits are specified at design stage.

Yes. Our control rooms are designed for transport and delivery to any accessible location in India. For very remote sites without crane access, we design the unit in transportable modules that bolt together on site. We have delivered to remote power generation sites, offshore support facilities, and mining projects across India and for export.

Standard single-room control rooms (20–80 sqm) are delivered in 21–35 days from design sign-off. Multi-room complexes with server rooms, battery rooms, and blast-rated construction take 35–45 days. Blast-resistant units with mass-plate construction take 45–60 days. We provide a milestone-based schedule at the time of quoting.

Yes. Our control rooms can be designed and documented to IEC 61439 (switchgear room), IEC 61340 (electrostatic discharge), IEC 60529 (IP rating), and IEC 61000 (EMC) standards. For ATEX-zone applications we specify compliant electrical fittings. Full IEC compliance documentation is provided for international project submissions.