For many, the path into the data center industry is far from linear – people arrive from a variety of backgrounds and experiences. For Gus O'Rourke, it was his passion for design and architecture that first led him to work with general contractors and fit-out specialists, eventually bringing him to Tate in late 2023.

Now serving as head of specifications, O'Rourke collaborates with architects and MEP consultants, delivering seminars to educate them on Tate’s product range and how it can support their design challenges.

Over the past 12-18 months, O'Rourke has observed a clear shift in data center technology, particularly the transition from CPU- to GPU-centric architectures, driving higher rack densities. In this episode of DCD>Talks, he shares his perspective on what it means to build future-ready data centers – and how Tate is helping its customers adapt through both air- and liquid-cooled infrastructure solutions.

The pace of change

The industry’s fairly recent shift toward liquid cooling has left many players grappling with the idea of submerging multi-million-dollar technology into unfamiliar mediums. As cooling technology becomes more advanced, increasingly complex machine learning models for AI also rise.

This evolution has pushed CPU racks from 15-20kW, to GPU racks that range from 135-200kW and demand significantly more heat removal to support the increased computational load – creating a continuous cycle of adaptation.

As a specialist in infrastructure distribution, Tate has taken this shift seriously. O'Rourke explains how these changes are reshaping the company’s work in the data center sector:

“As infrastructure demand grows, we’re seeing higher-density racks that require more power. Busways, for example, are going from 600 to 1200 amps. Cable trays are also becoming significantly heavier – previously around 74 to 87kg per linear meter, they're now exceeding 170kg. Everything is scaling up to meet these increasing requirements.”

This shift brings added infrastructure needs, such as manifolds to manage and distribute the flow of coolant. In response, Tate has begun manufacturing custom-engineered manifolds as part of its white space furniture offering. Returning to his design and architectural roots, O'Rourke contextualizes the issue:

“Switching from CPU to GPU racks significantly increases the building’s load due to the heavier equipment. This often means the original base build, approved through permits and tendered, isn’t structurally fit for purpose. As a result, the building’s structural capacity must be reinforced. So now, my role has expanded to collaborating with consultants and engineers to ensure all critical infrastructure is properly supported.”

Retrofitting in situ

In some cases, the pace of change is so fast that buildings are being retrofitted even as they are being constructed. Once CPUs are installed, O'Rourke has observed data center owners opting to upgrade racks row by row, rather than converting the entire facility to liquid cooling at once – largely because the building wasn’t originally designed to support higher-density racks.

To accommodate this reality, Tate carries out in-row upgrades by providing specialized structures to mount manifolds, which distribute coolant from air-cooled chillers throughout the data halls.

“Our role is to support the physical distribution of that cooling infrastructure,” explains O'Rourke. “Manifold systems can’t be supported by existing ceilings or hot aisle containment due to weight limits, so we’ve developed floor-mounted frameworks to hold them.” He adds:

“GPU racks also can’t replace all CPU racks one-to-one, as the building structure often can’t support the added load. Instead, GPUs must be strategically placed, and we’ve created solutions to support these selective upgrades.”

By designing manifold systems with actuators that integrate with the building management system (BMS), along with compatible hot aisle containment and ceiling structures, Tate has developed a seamless, integrated solution for the white space. This ensures a clear, efficient connection from the CDUs to the GPUs, allowing all mechanical and structural elements to work together cohesively.

Coordinated efforts

Bringing together complex solutions in a technically demanding environment requires seamless coordination across a diverse group of stakeholders, both internal and external. To successfully integrate the high-density designs needed in modern data centers, O’Rourke focuses on aligning the efforts of architects, engineers, and MEP consultants through a multi-pronged, innovation-driven, and globally informed strategy. This approach includes several key elements:

1. Leveraging global knowledge: As part of a global company deeply connected with hyperscalers and data center operators, Tate benefits from cutting-edge insights.
2. Knowledge transfer and education: Learnings from the US team are shared through talks and seminars delivered across Europe, ensuring consistent, up-to-date messaging – especially around technologies like liquid cooling.
3. Customer collaboration: By actively listening to customer needs, Tate rapidly develops and manufactures tailored solutions in response.
4. Agility and investment in innovation: Tate’s ability to quickly pivot and invest in new technologies – such as robot welding and manifold production – is supported by capital expenditure from its wider group.
5. Data center specialization: A sole focus on the data center sector enables Tate to engage deeply with industry-specific challenges and deliver localized solutions.

“We’re very lucky in the fact that Tate is a global company, and a lot of our knowledge is coming from the cloud and innovation team in the US. We have the ability not only to pivot and invest in innovation, but to deliver that in a very quick time frame,” says O’Rourke.

Trajectory predictions for the next year

While O’Rourke openly acknowledges that he’s not an engineer, he continually learns from the experts within Tate’s team. With rapid advancements – such as the emergence of 600kW to 1MW racks – he understands that change in the industry is both constant and unpredictable.

His role is to stay closely connected with architects, MEP consultants, data center operators, and hyperscalers to anticipate evolving needs and help craft practical, forward-thinking solutions. At its core, Tate remains a solution-driven company, committed to adapting swiftly and effectively to meet the challenges of a rapidly evolving data center landscape.

Watch the full DCD>Talks episode with Gus O'Rourke from Tate, here.