Advanced Cooling Towers and Open Racks: Fabrication Solutions for Modern Data Centers

Thermal management remains one of the biggest challenges for data centers today. With the rising processing demands and server densities, dependable cooling and airflow systems are paramount to delivering peak performance and uptime.

To meet these evolving demands, data centers rely on high-performance cooling systems and strategically designed open racks that promote airflow and reduce thermal strain.

Some data centers use significant amounts of water daily for cooling. One report stated that the average data center uses 300,000 gallons of water daily.

Alliance Fabrication and Manufacturing (AFM) supports this mission by fabricating precision components for cooling towers and open racks. With scalable capabilities, high-quality standards, and commitment to OEM partnerships, AFM helps data center manufacturers build modular and efficient infrastructure.

Cooling Towers: The Backbone of Efficient Thermal Management

The recommended temperature range for a data center is 64 - 80°F. Cooling towers play a critical role in dissipating heat from data centers. Unlike traditional air-based cooling systems, these towers use an evaporative process to cool water that absorbs heat from the facility.

Here’s how it works:

Heated water is pumped from the data center to the cooling tower.
Water is sprayed over a filling material (also known as packing or baffles), which breaks it into small droplets, increasing the surface area for better cooling.
Fans draw in cool air, which passes through the filter. As some water evaporates, it absorbs heat.
The resulting warm, moist air exits the top of the tower as visible steam.
The remaining cool water collects at the bottom and is recirculated into the system.

As energy demand grows, data centers must adopt cooling solutions that are both scalable and energy efficient. AFM helps meet this need by fabricating key structural and mechanical components for various types of cooling towers.

Fabricated Cooling Tower Components:

Alliance Fabrication and Manufacturing proudly partners with data center manufacturers to fabricate precision components for various cooling tower systems.

Our fabricated parts include:

- Structural support frames
- Fan mounting brackets
- Coil support brackets
- Anchor plates

Cooling Tower Types:

We support a variety of cooling tower configurations, including:

Open Circuit Cooling Towers – Dissipate heat efficiently through the evaporation of water.
Closed Circuit Cooling Towers – Use indirect cooling to maintain a clean cooling fluid.
Hybrid Cooling Towers – Combine open and closed-circuit technologies for enhanced efficiency.
Modular Cooling Towers – Scalable systems designed to grow with your cooling needs.

We strive to meet your cooling tower needs and want to ensure you get the pivotal solutions to your business.

Open Racks: Enhancing Airflow and Efficiency

Open racks are essential for effective airflow and thermal regulation. Unlike enclosed cabinets, open racks eliminate barriers to air movement, helping data centers maximize passive and active cooling strategies.

Key Benefits of Open Racks:

Improved Airflow: Open designs allow cool air to flow from the front and hot air to exit from the rear without obstruction.
Hot Spot Prevention: By eliminating side panels and doors, heat is not trapped between components, reducing the risk of equipment stress.
Energy Efficiency: Better airflow means HVAC systems work less, lowering energy usage and operational costs.
Custom Fabrication Features:

Brackets and rails tailored to various server dimensions

Perforated shelves and cutouts to support ventilation

Modular configurations for scalability and flexibility

Integrated cable management for airflow optimization

AFM’s precision metal component fabrication expertise ensures open rack systems are functional and adaptable to each client’s specific needs.

Why Data Center Leaders Choose AFM

Alliance Fabrication and Manufacturing was created to empower OEMs, fabricators, and manufacturers with high-quality, modular components that enhance performance and competitiveness. AFM

Backed by generations of experience and a commitment to data-driven decision-making, we serve as an extension of your team and deliver scalable, reliable fabrication solutions.

Include our Capabilities:

Robotic & Manual MIG Welding
Laser Cutting
Metal Forming & Bending
Mechanical Assembly
Stretcher Leveling for laser-quality flat steel
Quality Assurance

We operate from a 500,000 sq. ft. facility in the heart of the Midwest and are ISO 9001:2015 certified. Steel supplied directly from our sister company, Alliance Steel, located just steps away, provides our customers with a seamless material pipeline.

This integrated campus, combined with in-house processing and fabrication, dramatically reduces lead times and minimizes logistics delays. Plus, with stretcher-level steel readily available, we ensure laser-quality flatness and superior part consistency across every component we produce

Let’s Build the Future, Together

Build for performance. Fabricate for efficiency.

Partner with Alliance Fabrication and Manufacturing to bring reliable cooling systems and open rack infrastructure to life with precision-engineered components. Our vertical integration means we don’t outsource quality, it’s built into every bracket, panel, and frame we fabricate.

Looking to Start Your Project?

Whether your requirement is custom laser parts, welding services, metal bending, and forming, Alliance Fabrication and Manufacturing can meet your needs.

With our dedication to quality, time, and price, we strive to provide our customers with the best products at cost-conscious pricing.