Exploring Data Centre Rack Material Options

The performance of data centre racks can be highly dependent on what they are made from and how they are maintained. Here, we will examine the more common materials used for data centre racks and delve into the benefits of a promising alternative: Glass Reinforced Plastic (GRP).

Each rack material has its own set of benefits and trade-offs. Steel, the most prevalent choice, is prized for its strength, durability, and structural integrity. Cold-rolled steel, in particular, is often favoured due to its superior strength and resistance to deformation. 

Aluminium presents an alternative for those seeking lighter racks, offering the advantages of reduced weight and corrosion resistance, though it may not be as robust as steel. 

In modern applications, data centre racks might incorporate composite materials like glass reinforced plastic (GRP) to achieve specific properties such as improved strength-to-weight ratios, enhanced thermal management, and greater design flexibility.

While steel is the most prevalent material for data centre racks, it is not without its drawbacks:

• Weight: Steel is heavy, making it difficult to handle and transport. This can pose challenges during installation and maintenance activities, potentially increasing labour costs and downtime.
• Corrosion: Although steel can be treated to resist corrosion, it remains susceptible over time, particularly in environments with high humidity or exposure to corrosive substances. This can lead to degradation of the rack's structural integrity and necessitate costly repairs or replacements.
• Heat Conductivity: Steel is a strong conductor of heat, which can contribute to heat buildup within the rack. This may require more robust cooling systems to maintain optimal operating temperatures for the sensitive electronic equipment housed within the racks.
• Cost: High-quality steel can be expensive, and the manufacturing processes involved in creating racks add to the overall cost. Steel racks may, in some situations, be significantly more expensive than alternatives like aluminium or composite materials.
• Installation Complexity: The weight and rigidity of steel racks can complicate installation, often requiring specialized equipment, welding expertise, and additional manpower. This can lead to longer installation times and increased labor expenses.
• Flexibility: Steel's relative inflexibility can make it challenging to modify or adjust the rack structure once it is installed. This can be a disadvantage in dynamic data centre environments where changes and upgrades may be required.

Also Read: Material & Design Options for Data Centre Structural Ceiling Projects

Aluminium racks offer the advantage of being lighter than steel, but they have their own set of limitations:

• Strength: Aluminium is not as strong as steel, which can restrict the load-bearing capacity of the racks. This might be a concern for data centres housing heavy equipment or those with high-density configurations.
• Cost: While aluminium itself might be less expensive than steel on a per-pound basis, the need for thicker material to achieve comparable strength can drive up the overall cost.
• Susceptibility to Damage: Aluminium is a softer metal, making it more prone to dents, scratches, and other forms of physical damage. This can detract from the rack's appearance and potentially compromise its structural integrity over time.
• Thermal Conductivity: Aluminium, like steel, is a conductor of heat. While this can be beneficial in some cooling scenarios, it can also lead to heat spreading within the rack, potentially affecting the thermal management of sensitive components.
• Corrosion: Although aluminium is generally corrosion-resistant, it is not wholly immune to corrosion, especially in certain environments. Exposure to salty or acidic conditions can lead to corrosion, impacting the rack's longevity and performance.
• Joining and Welding: Aluminium can be more challenging to join, and weld compared to steel, which can complicate the manufacturing and customisation of racks.
• Electromagnetic Interference (EMI) Shielding: Aluminium provides less effective EMI shielding than some other materials. This can be a concern in data centres where minimizing electromagnetic interference is crucial for ensuring the reliable operation of electronic equipment.

Data centre construction project

Glass reinforced plastic (GRP) is an increasingly popular choice for data centre racks due to its numerous advantages over traditional materials. Below, we will explore the features and benefits of GRP in this context:

• Corrosion Resistance: GRP is highly resistant to corrosion, making it ideal for data centres where humidity or chemical exposure is a concern. This durability translates to longer lifespans and reduced maintenance costs for the racks.
• Lightweight: GRP is significantly lighter than steel, simplifying handling, transportation, and installation. This can result in lower labour costs and greater flexibility in data centre layouts.
• Electrical Insulation: The non-conductive nature of GRP provides excellent electrical insulation, enhancing safety by reducing the risk of electrical shocks and fires.
• Customisability: GRP can be created in a very wide variety of shapes and sizes, allowing for customised designs that optimise space utilisation and cable management. This flexibility can be particularly valuable in data centres with unique configurations or space constraints.
• High Strength-to-Weight Ratio: Despite being lightweight, GRP possesses a remarkable strength-to-weight ratio, providing sufficient structural integrity for most data centre applications without adding unnecessary bulk.
• Thermal Insulation: GRP offers good thermal insulation, helping to regulate temperature within the rack and potentially reducing the load on cooling systems, contributing to energy savings.
• Reduced Maintenance: GRP's resistance to corrosion and other environmental factors results in lower maintenance requirements compared to metal racks, further reducing long-term operational costs.
• Non-Magnetic Properties: GRP does not interfere with magnetic fields, which can be a significant advantage in certain data center applications where sensitive electronic equipment is used.
• Durability: GRP is resistant to wear, tear, and impact, making it a durable solution that can withstand the demands of a busy data centre environment.
• Aesthetic Appeal: GRP can be finished in various colours and textures, offering aesthetic flexibility for data centres where visual appearance is a consideration.

Watch this video to discover how GRP offers a comprehensive, end-to-end solution for your data centre needs:

As data centres continue to evolve and expand, the demand for innovative solutions that address the challenges of space constraints, energy efficiency, and equipment protection is growing. GRP is emerging as a promising material that offers a compelling alternative to traditional steel and aluminium racks.

By incorporating GRP into their infrastructure, data centre operators can benefit from improved safety, reduced maintenance costs, increased energy efficiency, and greater design flexibility. As the industry continues to prioritise innovation and sustainability, GRP is poised to play a significant role in shaping the future of data centre racks.

Interested in exploring GRP solutions for your data centre? Explore Fibergrate’s highly customisable structural shapes to learn more about our high-performance GRP products can transform your data centre infrastructure.