The modern data center is evolving faster than ever. AI workloads, GPU clusters, and high-performance computing are pushing server rack power density to new extremes — from the historical 5-7 kW per rack to 20-40 kW or more. Each increase in load magnifies one fundamental challenge: how to build safe, code-compliant grounding infrastructure that performs flawlessly under pressure.
Traditional grounding systems, once sufficient for smaller data halls, are no longer enough. With tighter inspection standards, higher energy demands, and zero tolerance for downtime, electrical reliability has become a defining feature of infrastructure performance.
If your installation process still relies on bending and drilling copper busbars on-site, you’re introducing variability at the exact point where precision matters most. Inconsistent fabrication can compromise NEC 250 compliance, delay commissioning, and increase total project cost.
Fortunately, there’s a better approach. Bolt-in, roll-formed grounding systems are designed for precision, consistency, code readiness, and delivery straight from the factory to the job site. By eliminating field fabrication, you reduce human error, accelerate installation, and ensure every connection performs to specification from day one.
Field-fabricated grounding might once have been “good enough,” but today’s rack designs, safety regulations, and uptime expectations demand more control. Below are the most common ways traditional methods fall short.
Codes like NEC 250 and TIA-607-F require torque-verified bonds and recorded resistance readings at each connection. Field-made busbars rely heavily on manual processes like drilling, cutting, and fitting, which can produce inconsistent results. A single failed ground impedance test can delay commissioning by weeks, create costly rework, and trigger additional inspection cycles.
High-frequency switching loads demand a continuous, low-impedance path. Factory-painted server frames can interrupt that continuity unless paint is removed at every contact point or serrated hardware is installed. Both methods slow down installation and risk damage to protective coatings. The result is added labor, messy metal debris, and unreliable conductivity.
As rack widths shrink to 600 mm or less, every millimeter becomes critical. Traditional grounding straps, jumpers, and lugs compete with high-volume power and fiber routing, restricting airflow and complicating maintenance. When technicians must remove cabling to reach a connection, small design inefficiencies turn into operational downtime.
Mounting bare copper grounding busbars to steel or aluminum frames invites galvanic corrosion, especially in humid or thermally dynamic environments. Over time, oxidation and electrochemical reactions degrade conductivity and increase resistance. These failures can remain hidden until a fault event exposes the system’s weakest link.
Grounding is the first line of defense against catastrophic faults. Undersized bars can vaporize during high-current events such as 10 kA faults, while oversizing adds unnecessary weight and cost. Field fabrication rarely optimizes this balance, leading to overengineered systems that increase both capital and installation costs.
Manual bending and drilling result in dimensional drift, uneven hole spacing, and mismatched fits. Each server rack requires time-consuming adjustments, stretching project schedules, and multiplying labor hours. In short, field fabrication trades precision for flexibility and often at the expense of consistency and cost efficiency.
The most effective way to eliminate these risks is to remove the guesswork from the job site entirely. Roll forming the parts can replace inconsistent, labor-intensive fabrication with a continuous, high-precision manufacturing process that produces identical parts every time.
Roll forming shapes flat metal coils into consistent, finished profiles by gradually passing them through a series of contoured rolls. Unlike press brakes or weldments that shape metal in a single, forceful step, roll forming molds it progressively. This not only reduces material stress; it also preserves dimensional integrity.
This process enables the creation of long, uniform components with tight tolerances and integrated features. The result is a component that fits perfectly every time, no matter how many racks you’re building.
Precise Fit: Factory tolerances as tight as ±0.005” ensure exact alignment with rack mounting points.
Repeatable Quality: Each piece is identical, eliminating site-to-site variation and reducing rework.
Integrated Design: In-line punching, slotting, and embossing reduce secondary machining steps.
Efficient Production: Roll forming yields only 0.5-3% material scrap – a critical advantage when working with pricey copper.
By using pre-engineered parts instead of field-modified components, contractors can standardize installation procedures and simplify documentation for inspection. This ensures every grounding connection meets NEC and TIA compliance requirements without delay.
Roll forming leverages the natural strengths of both copper and steel, making it ideal for high-density electrical environments where performance, weight, and space efficiency must align.
Copper’s extremely low resistivity makes it the preferred conductor for high-current distribution. Roll forming maximizes its advantages by producing uniform, high-precision profiles with minimal springback, ensuring an exact fit and consistent performance.
Unlike field-bent bars that develop hardened stress points, roll-formed copper maintains structural integrity throughout its length. For harsh environments, tin-plated copper provides an additional layer of protection against oxidation and galvanic corrosion, preserving low contact resistance for decades.
Each connection point is engineered to maintain a sub-milliohm path, supporting efficient power delivery while minimizing heat buildup. For facilities operating at 20-40 kW per rack, even small resistance reductions can lead to measurable improvements in energy efficiency and thermal management.
Galvanized steel channels are a cornerstone of grounding infrastructure. They provide mechanical strength, EMI/RFI shielding, and continuous electrical continuity in one compact profile.
Because roll forming maintains tight cross-sectional tolerances, channels attach flush and straight, eliminating the gaps that cause electromagnetic leakage or grounding failure. Integrated punching allows fast bonding without secondary drilling, and slim, custom designs preserve airflow through cable pathways.
Example: A hat-channel stiffener can add 20-30% structural load capacity to an existing rack without blocking cooling airflow or requiring welding, making it ideal for retrofits or seismic reinforcements.
|
Function |
Benefit |
Uses |
|
Structural Support |
High strength-to-weight ratio supports heavy loads efficiently |
Equipment mounting, framing, and overhead trays |
|
EMI/RFI Shielding |
Continuous uniform profiles prevent interference gaps |
Shielding frames and containment zones |
|
Integrated Grounding |
Pre-punched holes align with rack standards for consistent bonds |
Bolt-in connections, torque-verified grounding |
|
Airflow Optimization |
Slim profiles maintain critical cooling pathways |
Cable channels, hot/cold aisle design |
|
Retrofit Compatibility |
Hat and box channels can reinforce legacy racks |
Seismic upgrades and capacity expansions |
By combining multiple functions into one engineered component, roll-formed channels reduce part counts, simplify installation, and extend the life of your infrastructure.
Early collaboration between design engineers and roll forming specialists is the key to optimal performance and manufacturing efficiency. Consider these factors when designing busbars or grounding channels:
These considerations ensure a balance of electrical performance, manufacturability, and long-term mechanical stability.
Partnering for Proven ResultsNot all roll formers deliver the same level of precision, reliability, or supply chain coordination. Choosing the right partner ensures your infrastructure performs flawlessly and arrives when you need it. Dahlstrom Roll Form brings over 120 years of manufacturing experience to critical industries, combining engineering collaboration with dependable production quality.
By partnering with Dahlstrom, you gain a manufacturer who understands not just how to form metal but how to engineer for reliability, code compliance, and system longevity. |
Grounding reliability is more than a compliance requirement; it’s the foundation of every high-performance data center. As rack densities rise and standards tighten, roll-formed busbars and grounding channels provide the consistency and precision that field fabrication can’t match.
Ready to eliminate grounding headaches and streamline your next installation?
Visit our online Product Catalog to explore how bolt-in, code-ready solutions can help you build stronger, safer, and smarter data center infrastructure.