As the demand for data centers continues to rise, businesses are faced with a critical decision: retrofitting an existing facility or constructing a new one. Both approaches come with unique challenges and opportunities, especially when it comes to mechanical systems like HVAC, cooling, and piping—all of which are vital for maintaining data center uptime and performance. Mechanical contractors play an essential role in navigating these options, providing expertise in designing, installing, and managing the systems that keep data centers operational.

This blog explores the pros and cons of retrofitting existing facilities versus building new data centers, with a focus on the mechanical considerations that influence the decision.

The Case for Data Center Retrofits

Retrofitting involves adapting an existing facility to meet the specific requirements of a data center. While this approach can be cost-effective and sustainable, it demands careful planning and expert mechanical execution.

Advantages of Retrofitting

  1. Cost Savings
    • Retrofitting leverages existing infrastructure, which can significantly reduce upfront costs. Elements like the building shell, plumbing systems, and existing HVAC infrastructure can often be modified rather than built from scratch.
  2. Sustainability
    • Reusing an existing facility aligns with sustainability goals by minimizing demolition waste and the environmental impact of new construction. For instance, retrofits can incorporate energy-efficient mechanical systems that reduce long-term operating costs.
  3. Faster Deployment
    • Retrofitting can often be completed more quickly than new builds, as contractors can work within existing frameworks and avoid lengthy permitting processes associated with new construction projects.
  4. Location Advantage
    • Many older facilities are located in urban or suburban areas, providing proximity to end-users. This is increasingly critical as edge computing drives the need for localized data centers.
  5. Tax Incentives
    • Repurposing existing structures can qualify for financial incentives, such as tax credits. This is especially true when revitalizing former industrial sites that have been closed for years, like steel or textile facilities. While these incentives primarily benefit developers, they can also create opportunities for contractors.

Mechanical Challenges in Retrofits

While retrofits offer advantages, they come with mechanical challenges that must be addressed:

  • Space Limitations: Existing facilities may not have been designed with data center requirements in mind, leading to challenges in accommodating modern HVAC systems or high-capacity cooling solutions.
  • Aging Infrastructure: Older plumbing, piping, and HVAC systems may require significant upgrades to meet data center demands. For example, chilled water systems or CRAC (Computer Room Air Conditioning) units may need to be replaced entirely.
  • Custom Engineering: Retrofitting often involves custom solutions to integrate mechanical systems into an existing structure, which can be more complex than designing systems for a new build.

The Case for Data Center New Builds

Constructing a new data center from the ground up provides the opportunity to design and implement mechanical systems tailored to specific needs. This approach ensures no compromises are made in system design or performance.

Advantages of New Builds

  1. Optimized Design
    • New builds allow for the integration of the latest mechanical technologies, such as liquid cooling, direct-to-chip cooling, or free cooling solutions. These systems can be designed to maximize efficiency and reliability from day one.
  2. Scalability
    • New facilities can be constructed with scalability in mind, ensuring they can handle future growth in computing power and cooling requirements without major modifications.
  3. Energy Efficiency
    • Modern designs can incorporate state-of-the-art energy-efficient systems, such as economizers and renewable energy integration. This helps meet stringent environmental standards and reduces operating costs.
  4. Code Compliance
    • New builds offer the advantage of meeting the latest building and energy codes without needing costly upgrades or modifications to existing systems.

Mechanical Considerations for New Builds

  • Higher Upfront Costs: The initial investment in mechanical systems for a new build can be substantial, but the long-term operational savings often justify the expense.
  • Time to Completion: Building a new facility typically takes longer than retrofitting due to site preparation, permitting, and construction timelines.
  • Specialized Expertise: Designing mechanical systems for a high-density data center requires expertise in thermal management, redundancy planning, and airflow optimization.

Comparing the Two Options: Key Mechanical Factors

When deciding between a retrofit and a new build, businesses must evaluate the following mechanical factors:

  1. Cooling Requirements
  2. Redundancy and Reliability
    • Data centers demand redundancy in mechanical systems to prevent downtime. New builds can integrate these redundancies seamlessly, whereas retrofits may require creative solutions to achieve the same reliability.
  3. Energy Usage Effectiveness (EUE)
    • Retrofitting may improve the energy efficiency of an older building, but new builds have the potential to achieve superior EUE ratings by incorporating cutting-edge mechanical designs.
  4. Space and Layout Constraints
    • Retrofitting often involves working around existing structural limitations, which can complicate the installation of piping and HVAC systems. New builds, on the other hand, allow for optimized layouts.

Innovation at Our Core

At Cadence, innovation and values guide everything we do. Mechanical contractors play a pivotal role in ensuring the success of both retrofits and new builds, and our team takes that responsibility to heart. Our core value, “Innovation at our Core,” reflects our commitment to:

  • Safety for All: We prioritize the well-being of people, both in the workplace and the communities we serve.
  • Employee Growth: Investing in the personal development of our employees ensures they bring cutting-edge expertise to every project.
  • Strong Relationships: We build lasting connections with families, customers, partners, and communities, ensuring every project contributes to a larger purpose.

By aligning our mechanical expertise with these core values, we provide solutions that not only meet technical requirements but also create a lasting positive impact.

The Role of Mechanical Contractors in Decision-Making

Mechanical contractors are critical in evaluating the feasibility of retrofits versus new builds. Their expertise ensures mechanical systems meet the specific needs of the data center, balancing cost, efficiency, and reliability. Contractors assess factors like:

  • The capacity of existing HVAC and piping systems in retrofits.
  • The design and scalability of mechanical systems in new builds.
  • Compliance with local and national building codes.

Additionally, contractors play a pivotal role in integrating energy-efficient technologies and ensuring smooth installation and maintenance processes.

Making the Right Choice

The decision between retrofitting an existing facility or building a new data center depends on several factors, including budget, timeline, location, and long-term goals. Mechanical contractors provide invaluable insights and expertise, ensuring mechanical systems are tailored to the unique needs of each project.

Both retrofits and new builds have their place in the evolving landscape of data centers. By understanding the mechanical implications of each approach, businesses can make informed decisions that align with their operational and sustainability goals.