Data Center HVAC Design: Don't Neglect the Infrastructure

3 min read

Nov 5, 2025 8:00:00 AM

Why HVAC Design Makes or Breaks Data Center Performance

Data centers power the digital services we rely on every day, from cloud computing to Netflix streaming. As heat output increases with every generation of servers, cooling systems now play a critical role in uptime, energy efficiency, and long-term operating costs.

Did you know the physical infrastructure of your server racks and cooling system is just as important as the technology itself? Traditional HVAC manufacturing, however, often falls short in data farms.

Data centers require components that are corrosion-resistant, dimensionally precise, vibration-tolerant, and capable of forming airtight seals. In this article, we’ll discuss how roll forming solves these challenges by producing accurate, consistent HVAC components at scale.

Key HVAC Components in Data Centers

For data centers and adjacent energy storage environments (e.g., power supply rooms), structural components support airflow management, structural stability, and system reliability. Pay close attention to these elements of your infrastructure:

Airflow & Ducting

Strong, leak-resistant ductwork
Cooling tower louvers
Dampers and airflow control components

Equipment Casings & Frames

Air conditioner housings
Electric heater frames
Filter frames for high-density cooling systems

Thermal Containment Structures

Hot/cold aisle containment frames
Door frames featuring sealing grooves for perforated panels
Profiles designed to minimize leakage and improve pressure control

Structural & Support Components

Brackets for HVAC equipment
Rails for chilled water piping or in-row coolers
Mounting channels for thermal panels, fans, or sensors

Heat Pump Components

Cabinets, rails, vertical members, and protective cases
Structural chassis and mounting hardware

Shameless plug: All of these parts are a match for the roll forming manufacturing process. Data center infrastructures benefit from roll forming’s strength, precision, and scalability to ensure continuous airflow management, structural stability, and system reliability.

4 Data Design HVAC Design Tips

1. Build Airflow and Thermal Efficiency Inside Rack Systems

Even outside the HVAC room, cooling effectiveness depends heavily on rack-level infrastructure and airflow management.

Slim reinforcement profiles maintain cable access and airflow pathways for legacy racks, unlike bulkier alternatives that can obstruct air circulation and raise equipment temperatures.
Tight tolerances ensure minimal leakage around doors, panels, and containment structures, improving cooling efficiency and lowering energy consumption.

Together, these enhancements support reliable rack-level thermal performance.

2. Pick Durable Materials

Choosing the right material is vital for durability, efficiency, and longevity in HVAC systems. Only work with materials suited for high-performance data center HVAC systems.

Material	Advantages	Best Use
Galvanized Steel	Corrosion-resistant, long service life, easy to fabricate	Standard ductwork and structural components
Galvalume Steel	Excellent corrosion resistance, strong, and cost-effective	Large-scale cooling infrastructure
Stainless Steel	Hygienic, corrosion-resistant, durable	Environments requiring high cleanliness or chemical resistance
Copper	Antimicrobial, superior heat transfer	Sensitive environments, refrigerant tubing

Make sure your structural channel manufacturer has machines and processes that are compatible with the material you choose.

3. Keep Compliance and Safety Top-of-Mind

Data center HVAC systems must meet strict industry standards. Compliance means following national, international, and industry regulations that protect data, ensure reliable operations, and support environmental goals.

This includes security standards like SOC 2 and ISO 27001, data rules such as HIPAA and GDPR, and energy guidelines from groups like ASHRAE.

To meet these requirements, every physical system, HVAC included, must be accurately documented and built to specifications that keep the facility secure and dependable.

Your manufacturing method should aid compliance by delivering:

Repeatable parts held to exact tolerances
Profiles engineered for specific safety or certification requirements
Features like hemmed edges for improved technician safety
Materials that support corrosion and fire-resistance standards

This precision helps operators meet regulatory requirements without adding complexity to the manufacturing process.

3 Ways Roll Forming Cuts HVAC System Costs

Cost control is a top priority for data center engineers and facility managers. Roll forming reduces total HVAC system cost through three major advantages.

1. Minimal Material Waste

Continuous coil-fed manufacturing generates far less waste than traditional cutting and forming methods (which create up to 50% scrap). When working with materials like stainless steel or copper, reduced scrap translates into meaningful savings.

2. Fewer Secondary Operations

Sheet metal punching, notching, cutting, and even certain fastening features can all be integrated in-line. This reduces labor, shortens lead times, and minimizes human error – improving quality, lead time, and cost efficiency.

3. Faster Installation

Roll-formed components arrive ready for assembly, with built-in features that allow technicians to install systems more quickly and with fewer adjustments. The result is decreased installation time and lower on-site labor costs.

4. Plan for Installation and Maintenance

Because roll-formed components offer consistent, precise dimensions, they help ensure that both new installations and future upgrades are easier to plan and execute. In-line punched features—such as holes, notches, or slots—also support flexible assembly and simplified disassembly as equipment needs evolve.

Together, these qualities reduce downtime, improve long-term serviceability, and lessen labor demands on facility teams as systems change over time.

Support Your Data Center HVAC System Long-term

Follow these tips to create a cost-effective, highly precise manufacturing solution for data center HVAC systems. By improving airflow control, reducing waste, shortening installation time, and meeting strict industry standards, your HVAC design – down to the smallest component – should help the cooling infrastructure perform reliably at scale.

If your data center is facing high thermal loads and rising energy costs, consider investing in roll-formed HVAC components as a strategic choice that enhances efficiency, lowers operational risk, and supports long-term system performance.