Overview
A national data center contractor needed a fast-turnaround hot-aisle containment system for a new expansion project supporting an enterprise cloud computing customer. The site required a scalable, code-compliant solution that would integrate seamlessly with existing server racks and be installable by contractor teams with minimal disruption to ongoing facility operations.
PowerSafe Automation was selected to engineer, manufacture, and pre-assemble a turnkey containment package—including support framing, twin-wall polycarbonate panels, blanking panels, and sliding access doors—designed for rapid installation with no on-site fabrication required.
Customer Profile
- Industry: Data Center Construction & Integration
- Location: United States
- Project Type: New expansion build (~2MW)
- Primary Objective: Improve cooling efficiency & rack utilization via hot-aisle isolation
Challenges
The contractor faced several challenges common to new build + retrofit deployment:
| Challenge | Description |
| Compressed timeline | Deployment needed to be completed inside a 6-week window |
| Mixed rack footprint | Existing rack models and spacing required adaptable framing |
| Limited on-site fabrication | Welding and machining not permitted in the active environment |
| Cooling inefficiencies | High bypass airflow was increasing energy consumption |
| Required scalability | System needed to support future growth and rack reconfiguration |
Traditional welded steel structures were ruled out due to weight, fabrication requirements, and limited flexibility.
Solution: Engineered Modular Hot-Aisle Containment
PowerSafe Automation designed a turnkey HVAC-optimized enclosure system built on T-slotted aluminum extrusion with twin-wall polycarbonate paneling. The modular architecture allowed rapid deployment without specialized tools.
System Elements Delivered
- Engineered drawings & field measurements
- T-slotted aluminum extrusion framing
- Twin-wall polycarbonate upper panels
- Universal rack-mount blanking panels
- Automatic sliding access doors
- Brush & gasket sealing kits
- Cable management pass-throughs
- Installer instructions + labeling
All components were pre-cut, labeled, and sub-assembled, enabling the contractor to receive shipment on site and immediately begin install.
Project Execution
1) Engineering & Modeling
PowerSafe engineering reviewed contractor drawings, rack layouts, and airflow requirements. A 3D CAD model defined:
- Component sizing
- Door swing/slide clearances
- Return air plenum alignment
- Sealing strategies
- Rack-to-structure connection points
Final designs were stamped and approved before fabrication.
2) Manufacturing & Sub-Assembly
PowerSafe manufactured components in-house, including:
- Aluminum extrusion cut to length
- Hardware kits pre-organized & labeled
- Door assemblies fully pre-built
- Polycarbonate panels cut and edge-sealed
Major assemblies were test-fit in the shop prior to shipment to verify accuracy.
3) Pre-Shipment Packaging
Systems were shipped as kitted packages, each labeled for location and assembly sequence:
- Zone-labeled extrusion frames
- Matching panel sets
- Door modules packaged individually
- Field install drawings + BOMs
Packaging minimized staging time and allowed work to begin immediately upon receipt.
4) Contractor Installation
Once delivered, the contractor:
- Positioned pre-numbered extrusion assemblies
- Installed doors using plug-and-play mounting
- Attached pre-cut panels
- Sealed gaps using provided trim & brush kits
No welding, machining, or painting was required. Standard hand tools completed the work.
Results
| Outcome | Value |
| Install Time Reduced | ~60% faster vs. welded platforms |
| Cooling Efficiency | ~27% reduction in cooling energy |
| Rack Density Increase | Additional racks deployed within same footprint |
| Minimal Downtime | Installation performed while facility remained active |
| Easy Scalability | Additional rows added later using same modular architecture |
The containment system provided immediate airflow isolation, decreasing bypass flow and stabilizing server inlet temperatures across all racks within the zone.
Raising the CRAH setpoints post-installation yielded significant reductions in cooling power consumption.
Why PowerSafe Automation
- Turnkey mechanical design + fabrication
- Industry-leading T-slot extrusion competency
- Rapid CAD modeling & sub-assembly production
- Fast shipping to contractor sites
- Standardized accessory integration
- Long-term expandability
PowerSafe’s integrated engineering + manufacturing workflow enabled a faster, cleaner, and more scalable deliverable versus conventional fabrication.
Key Value Delivered
- Pre-engineered + pre-assembled = fast install
- Eliminated on-site fabrication
- Reduced labor + staging cost
- Improved airflow containment & efficiency
- Scalable framework for future expansion
- Repeatable design for multi-site deployment
Conclusion
This project demonstrates how modular extruded containment systems allow data center contractors to deploy advanced cooling solutions rapidly while minimizing on-site disruption. Through engineered design, pre-assembly, and contractor-friendly packaging, PowerSafe Automation delivered a high-performance hot-aisle enclosure that improved cooling efficiency, supported increased rack densities, and created a scalable platform for future buildouts.
PowerSafe’s ability to provide engineered, manufactured, and ready-to-install modular systems proved invaluable for the contractor—reducing risk, simplifying installation, and delivering measurable operational improvements.
