Question 1

The challenge

Accepted Answer

The customer was preparing to commission a new data hall designed to support next-generation, liquid-cooled server technology driven by high-density AI workloads. As a first-of-kind deployment, the testing process carried significant risk. Any contamination or debris introduced into the permanent cooling loop could result in equipment damage, voided warranties, system failures, or costly redesigns.

Traditional air-cooled testing methods were no longer viable, and no industry standard existed for liquid-cooled load bank testing at this scale. The customer required a solution that could validate performance under real operating conditions while maintaining absolute control over cleanliness, contamination, and physical space constraints inside live data halls.

Question 2

The solution

Accepted Answer

Aggreko engineered and delivered a fully custom liquid-cooled load bank testing solution designed specifically for hyperscale environments. The system included 16 × 500 kW liquid-cooled load banks paired with eight stainless steel heat exchanger skids, each designed with a compact footprint to fit through doorways, inside data halls, and between server racks.

All wetted materials were constructed from 304 stainless steel to meet strict contamination specifications. The solution required no on-site generation, leveraging available site power, and was supported by extensive engineering review, third-party testing, chemical flushing, and on-site validation. Aggreko’s on-site operators supported sequential testing across data halls, relocating and re-tying equipment as construction progressed.

Question 3

The impact

Accepted Answer

Aggreko’s solution enabled the customer to safely execute first-of-kind liquid cooling validation without introducing risk to permanent infrastructure. The testing program delivered critical performance data to support future scale deployments while protecting warranties and preventing downstream failures.

By completing the full testing program within a one-month construction window, Aggreko helped maintain project momentum and avoided delays that could have triggered costly redesigns or supplier changes. The result was increased confidence in liquid cooled data hall design, reduced commissioning risk, and a proven testing approach that can be replicated across future hyperscale facilities.

Key facts:

Over 12 months of engineering design and validation
Zero contamination incidents during testing
Sequential testing completed across multiple data halls
Compact skid footprint enabling in-hall operation

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Engineering confidence for liquid cooling

Overview

The challenge

The solution

The impact

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