Rodney Willis, VP of sales and sourcing at Align’s data center design-build group, began his career in 1996 in copper and fiber optic manufacturing.

More than twenty years later, a tap on the shoulder led him into the data center industry, where he has played a key role in Align’s expansion and innovation. Originally a client of Align, Willis transitioned to the team about 15 years ago, bringing firsthand experience just as data centers were transforming from small, single-room setups into the expansive, high-tech environments we know today.

Now, Align’s data center design-build group specializes in the critical “white space” – the critical areas of data centers where equipment, cabling, and connectivity live.

In a rapidly growing market with intense demand for essential materials like busway systems and fiber optic cabling, Willis emphasizes the importance of a robust sourcing strategy to keep projects on track and meet the industry’s ever-growing needs, highlighted in this DCD>Talk.

Adapting design for high-density applications

The rapid rise of AI and high-density computing is transforming data center white space, especially in cooling, cabling, and power delivery. Traditional data center designs are being redesigned to handle the demands of high-density setups, where more equipment is packed into smaller spaces.

Cooling requirements

In the past, water near sensitive hardware was avoided at all costs. Now, liquid cooling has become a necessity, with water being brought right to, and even into, the racks to support growing density needs. Willis explains:

“This shift has evolved data centers from supporting around 1.3 megawatts in 10,000-square-foot spaces to setups focused on liquid-cooled racks capable of managing megawatts in linear rows.”

New cooling methodologies, such as rear-door heat exchangers, are vital in these high-density environments, where infrastructure is customized to meet specific client requirements.

Cabling challenges

With more power and data cabling in each cabinet, careful design is essential to maintain airflow, as excessive cabling can obstruct fan intakes, leading to overheating and potentially significant operational issues.

“I still often see people using 24-inch-wide cabinets because that’s the space they have, but there’s only so much you can fit in there. When you’re adding three power supplies and multiple PDUs – sometimes six in a single cabinet – you quickly run out of room,” emphasizes Willis. “The depth of the cabinet becomes critical, too. Every component impacts the next. Power setup affects cabling, which in turn affects cooling. It all has to work together seamlessly.”

Power delivery

Robust power solutions are essential in high-density designs. Options like busways, high-capacity modular systems capable of carrying 2,000 amps, or flexible conduit whips are considered for their ability to meet the growing power needs of data centers. Willis summarizes:

“Every component (cabling, busways, PDUs, and power sources) directly impacts overall performance and has to work seamlessly together. A change or upgrade in one area affects the functionality of the entire system.”

Navigating customer needs in data center design

Customer preferences significantly influence design choices, especially with innovations like liquid cooling. According to Willis, some clients prefer liquid cooling routed through raised floors rather than above the racks for added peace of mind:

“With today’s fast-paced environment, a second or third set of eyes is crucial to avoid costly mistakes. We make sure the design aligns with the customer’s intent, down to the smallest detail.”

AI compute cabinets can weigh up to 4,800 pounds, raising concerns about floor load capacity. Raised floors offer flexibility for cabling, cooling, and power management but may struggle with the weight demands of high-density setups. Slab floors are sturdier but come with their own design and cost challenges, particularly for liquid cooling, which can pose risks if leaks occur.

This isn’t just a financial concern – it’s also about safety.

“As we integrate various trades and systems into the same space with multiple teams working alongside each other, safety becomes paramount. Proper structural load assessments and seismic bracing, especially in earthquake-prone areas, are essential to ensure the raised floor can handle the weight,” Willis emphasizes.

What does this mean for the future of IT racks?

As the landscape of high-performance computing continues to grow and evolve, so too do the designs of data center cabinets. These changes are driven by the need for deeper and wider cabinets that can support a greater number of power distribution units (PDUs) and cabling. The emphasis is not just on accommodating equipment, but also on optimizing space and power capacity to avoid the network distance limitations that can arise when cabinets become too wide.

In essence, the challenge lies in finding that sweet spot – maximizing space utilization while considering practical network and structural constraints. As we look ahead, it’s clear that the future of IT racks will require innovative solutions that keep pace with these evolving needs.

To learn more about the evolution of data center white space, watch the full DCD>Talk here.