Contributors: John Floren, David Story

Aging data centers are at a crossroads. Once the backbone of enterprise operations, many are now grappling with a relentless surge in power demands, evolving regulations, rapid technological advancements, and ever-growing workloads. For the professionals tasked with keeping these facilities running smoothly, the challenges are complex and unrelenting: balancing uptime, efficiency, compliance, and cost, all within the limits of aging infrastructure and stretched budgets.

Despite the hurdles, there’s good news: legacy facilities don’t have to fall behind. With thoughtful strategies and targeted upgrades, outdated data centers can adapt to today’s demands. Here’s a closer look at the obstacles they face—and the solutions that are making an impact.

Power and cooling constraints

The challenge: Older data centers were never designed to support the energy-intensive demands of today’s data workloads. Originally built for power densities around 30 watts per square foot, many now face workloads exceeding 150 watts per square foot. This discrepancy puts enormous pressure on aging infrastructure, resulting in inefficiencies, higher operational costs, and increased risks of overheating and downtime.

Solutions making an impact

  • Hot/cold aisle containment. By isolating hot and cold airflows, this straightforward upgrade prevents mixing air heated by equipment and the air cooled by HVAC systems, significantly improving cooling efficiency. The result? A boost in power utilization efficiency (PUE) by 25%.
  • Retro-commissioning. During the normal course of business, it’s common for multiple uncoordinated changes to be triggered by construction projects, repairs, and maintenance (or lack thereof). This can inadvertently lead to inefficient and ineffective HVAC systems. A thorough reassessment of cooling systems can uncover inefficiencies, optimize airflow, and fine-tune temperature setpoints, reducing strain on aging systems and cutting operating costs.
  • Dynamic cooling management. Deploying intelligent cooling management systems can monitor workloads and environmental conditions in real-time, automatically adjusting cooling operations to minimize energy consumption.
  • Onsite energy production with microgrid integration. For facilities facing grid constraints, microgrids offer a flexible and resilient energy solution. Microgrids can integrate a mix of localized energy generation technologies, including solid oxide fuel cells, hydrogen-based systems, solar photovoltaics, and emerging ultralight nuclear options. These systems operate independently or in conjunction with the grid, providing backup power during outages and supporting peak demand. By implementing microgrid solutions, data centers can reduce reliance on external power sources, enhance energy resilience, stabilize operational costs, and significantly improve sustainability by incorporating renewable or low-emission energy technologies.

Context matters

The effectiveness of these solutions depends heavily on geography and existing facility layouts. For instance:

  • Climate. Data centers in cooler climates may benefit from free cooling solutions, leveraging outdoor air for heat dissipation, while those in hotter regions must rely more heavily on robust HVAC systems.
  • Power availability. Facilities in regions with unreliable grid infrastructure may need to prioritize microgrid solutions or on-site generation to maintain uptime.
  • Space constraints. Older facilities with limited space may need to explore compact technologies like liquid cooling or modular equipment upgrades to maximize efficiency without extensive renovations.

By addressing these power and cooling limitations with targeted strategies, data centers can not only extend the life of their existing infrastructure but also operate more sustainably and cost-effectively.

Retrofitting without downtime

The challenge: For aging data centers, retrofitting can feel like performing “open-heart surgery”—keeping critical systems operational while making necessary upgrades. This already complex task is complicated by aging equipment that may be nearing the limits of its performance, leaving little room for error. Maintaining uptime during these projects requires meticulous planning and execution.

Solutions making an impact

  • Phased implementation. Upgrading one system at a time—while ensuring redundancy in power and cooling systems—can minimize risks. This approach allows operators to maintain critical operations without overloading existing infrastructure.
  • Temporary solutions. Deploying temporary cooling units, backup generators, or modular power systems ensures uninterrupted performance during retrofitting. These stopgap measures provide essential support while permanent upgrades are underway.
  • Expert assessments and planning.Involving skilled engineers with experience in live retrofits can make a big difference. These professionals can conduct detailed site evaluations, create phased upgrade plans, and coordinate with facility teams to minimize operational disruptions. Their expertise ensures a smooth transition with minimal risk to uptime.

Context matters

The strategies for retrofitting without downtime need to be tailored to the specific circumstances of each facility. For example:

  • Facility size and age. Larger, older facilities with sprawling layouts may require more extensive planning to maintain redundancy, while smaller data centers might benefit from modular upgrades.
  • Existing redundancy levels. Facilities with built-in redundancies (e.g., dual power feeds or N+1 cooling systems) have more flexibility for phased implementation, while those without may need temporary solutions to ensure uninterrupted operations.
  • Workload sensitivity. Critical applications that cannot tolerate any downtime may require additional investments in temporary capacity or more conservative phasing to protect system reliability.

By carefully considering these factors, operators can ensure their retrofitting efforts align with the unique demands of their data centers, enabling essential upgrades without compromising performance.

Compliance with current regulations

The challenge: Environmental and efficiency regulations are evolving rapidly, putting pressure on aging data centers to meet new standards. States like California and Washington are implementing stringent rules around refrigerants, economizers, and energy efficiency. Older facilities, built before these standards existed, often face significant hurdles in achieving compliance without major overhauls.

Solutions making an impact

  • Proactive audits. Regular assessments of infrastructure and operations can help identify potential compliance gaps early. These audits allow operators to prioritize upgrades and avoid costly penalties while staying ahead of regulatory changes.
  • Creative design solutions. Retrofitting systems with energy-efficient components, such as economizers for free cooling or fan-driven cooling systems, can reduce energy use and align facilities with modern standards. Such solutions can also help operators take advantage of incentives or rebates for energy efficiency improvements.
  • Supplier coordination. Partnering with a skilled engineer who has relationships with manufacturers and suppliers can align upgrades to source compliant components and identify tailored recommendations, such as refrigerants with a lower global warming potential (GWP), to meet environmental requirements.

Context matters

The impact of regulations and the best approach to compliance will depend on several factors:

  • Regional variations. Regulations differ widely between states and countries. Facilities in areas with stricter or evolving standards (e.g., California, Canada) may need to adopt advanced cooling technologies or alternative refrigerants sooner than others.
  • Facility age. Older systems may require extensive retrofits, while newer facilities might only need minor adjustments to meet evolving standards.
  • Operational priorities. Facilities with high workloads may need to balance compliance efforts with uptime demands, ensuring upgrades do not disrupt critical operations.

By staying proactive and tailoring compliance strategies to their unique circumstances, data centers can navigate regulatory changes while minimizing disruption and maintaining efficiency.

Limited physical space

The challenge: As IT equipment becomes more compact yet increasingly power-intensive, many data centers face the paradox of having large floor areas but insufficient power and cooling capacity to support additional systems. This mismatch leads to underutilization of available space. Furthermore, older facilities often suffer from cluttered layouts and cabling inefficiencies, leaving little room for expansion or modernization.

Solutions making an impact

  • Space optimization. Identify and repurpose adjacent areas, such as unused storage rooms or administrative spaces, to house critical systems. Creative reallocation of non-essential areas can free up valuable floor space for IT infrastructure.
  • Vertical expansion. In facilities with sufficient ceiling height, installing mezzanines or secondary roofs can add usable space without requiring significant new construction. This approach maximizes existing square footage and can be paired with advanced cooling solutions to maintain efficiency.
  • Equipment consolidation. Upgrading to modern, energy-efficient equipment can dramatically reduce the physical footprint of IT infrastructure. Replacing legacy systems with high-performance, compact hardware not only frees up space but also enhances power and cooling efficiency.

Context matters

The feasibility and effectiveness of space management strategies will depend on factors such as:

  • Building architecture. Facilities with high ceilings or flexible floor plans are better suited for vertical expansion or modular upgrades.
  • Power and cooling infrastructure.Adding more systems may require concurrent upgrades to power and cooling capacities, ensuring new equipment can operate reliably.
  • Future growth. Space management plans should accommodate both immediate needs and long-term growth, ensuring flexibility for future scaling.

By optimizing space and aligning infrastructure with modern equipment requirements, data centers can overcome physical constraints, improve efficiency, and remain competitive in an increasingly demanding environment.

Maintenance complexity and equipment lifespan

The challenge: As data centers age, their equipment often demands more frequent maintenance, driving up operational costs and straining resources. Compounding the issue, replacement parts for older systems can become increasingly difficult to source, heightening the risk of prolonged outages and reduced system reliability. Managing these complexities requires a proactive and strategic approach to ensure uptime and operational efficiency.

Solutions making an impact

  • Preventive maintenance programs. Regular inspection and maintenance of equipment, including cleaning heat rejection systems and monitoring for performance issues extends the lifespan of aging systems and reduces the likelihood of unexpected failures.
  • Stocking spare parts. Maintaining an inventory of critical components ensures rapid response to repair needs, minimizing downtime and avoiding delays caused by supply chain disruptions.
  • Ongoing commissioning. Implementing advanced monitoring systems such as smart building controls, sensors, and predictive analytics can provide real-time insights into equipment operation and environmental conditions. By analyzing data trends and identifying inefficiencies or deviations, teams can proactively address alarms and potential issues before they escalate into critical failures. This ongoing commissioning approach ensures that systems operate at peak efficiency, extends equipment lifespan, and reduces unplanned downtime.

Context matters

The approach to managing maintenance complexity will depend on several factors:

  • Equipment age and condition. Older systems may require more intensive monitoring and a larger inventory of spare parts, while newer systems might benefit from advanced predictive analytics tools.
  • Operational scale. Larger facilities with more equipment may need comprehensive maintenance schedules and automation tools to handle the complexity, whereas smaller data centers might prioritize manual monitoring and simpler maintenance programs.
  • Managing vendor relationships. Partnering with equipment manufacturers or third-party maintenance providers can ensure access to hard-to-find parts and expertise, reducing repair times and enhancing system reliability.

By adopting a proactive maintenance strategy and leveraging technology to monitor and manage aging systems, data centers can extend equipment lifespans, mitigate risks, and control operational costs.

How Salas O’Brien can help

For aging data centers, optimizing airflow and cooling efficiency offers some of the most impactful improvements. Simple upgrades like hot/cold aisle containment or raising temperature setpoints can significantly reduce operating expenses and extend the life of existing systems.

Salas O’Brien’s experts can help you address these challenges systematically in order to transform aging facilities into efficient, sustainable hubs that support evolving business needs. Reach out to our contributors below.

For media inquiries on this article, reach out to Stacy Lake, Director of Corporate Communications.

Contributors
John Floren, PE

John Floren, PE

John Floren is an expert in the design of complete power systems in critical environments where uninterrupted service to facilities is critical. With extensive expertise, he is leading engineering design for some of the most technically complex telecom and data center projects in the world. John serves as a Principal at Salas O’Brien. Contact him at [email protected].

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David Story, PE, LEED AP

David Story, PE, LEED AP

With over 22 years of experience in mechanical engineering design and project management, David Story brings a client-centered approach to every project. His expertise spans managing both small-scale and large-scale design and construction projects. David serves as a Principal at Salas O’Brien. Contact him at [email protected].

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