When a rapidly scaling AI company needed to deploy 15MW of critical IT load into a legacy facility to support its compute-intensive operations, they turned to Vinco and VADD Construction Services. With a tight timeline of under four weeks to evaluate, procure, and begin implementation, our team leveraged deep industry expertise,

rigorous engineering analysis, and agile project management to meet the challenge head-on. This case study highlights how we assessed the market, conducted detailed site evaluations, and engineered a high-density, reliable solution—currently in progress—capable of supporting densities upwards of 100kW per rack.

The AI sector moves at breakneck speed, and our client was no exception. Their need for 15MW of additional IT capacity stemmed from an urgent requirement to power advanced AI workloads in an existing legacy data center. The facility, while operational, was not originally designed for the extreme power and cooling demands of modern high-performance computing.

With only four weeks to act, Vinco and VADD faced a multifaceted challenge: identify viable options, ensure structural and electrical integrity, and design a redundant DLC N+1 environment—all while navigating supply chain constraints and a ticking clock.

Vinco and VADD deployed a multidisciplinary team of engineers, procurement specialists, and project managers to execute a streamlined yet thorough process:

Market Evaluation and Site Walkthroughs

Within days, our team canvassed the market for equipment and toured multiple data centers to benchmark capabilities and identify the best fit for retrofitting. These walkthroughs included detailed assessments of existing infrastructure—everything from electrical panels to cooling systems—ensuring no stone was left unturned.

Engineering Analysis and Red Flag Reports

Our engineering team conducted an exhaustive review to de-risk the project:

• Electrical Panel Reviews: We analyzed load capacities, breaker configurations, and fault tolerances to confirm the legacy electrical systems could handle a 15MW upgrade without compromising stability.
• Chiller Inspections: Cooling is the backbone of high-density IT environments. We inspected existing chiller units for efficiency, capacity, and compatibility with the projected heat loads of 100kW+ per rack, identifying potential bottlenecks early.
• Floor Weight Load Assessments: Retrofitting a legacy facility meant verifying that the raised floor could support the weight of new high-density racks and ancillary equipment. Our structural engineers calculated load distributions and flagged areas requiring reinforcement.
• Red Flag Reports: These comprehensive analyses were compiled into actionable reports, giving the client clear visibility into risks and mitigation strategies.

Design and Procurement

Armed with data, we designed a DLC N+1 environment—offering redundancy to ensure uptime even during component failure—and specified equipment capable of supporting rack densities exceeding 100kW. Our procurement team moved swiftly, leveraging industry relationships to source critical components like PDUs, UPS systems, and cooling units despite global supply chain pressures.

Implementation (In Progress)

As of now, installation is underway. Our team is working around the clock to integrate this 15MW capacity into the legacy facility, adapting to real-time challenges while maintaining strict adherence to safety and performance standards. While the final ribbon-cutting is still ahead, the project is on track to deliver a robust, future-proof infrastructure for our AI client.

• Speed: From initial consultation to boots-on-the-ground installation in under four weeks.
• Precision: Detailed engineering reviews—spanning electrical, cooling, and structural domains—ensured a no-surprises approach.
• Innovation: Designing for 100kW+ rack densities positions the client at the forefront of AI compute capabilities.
• Reliability: The N+1 redundancy framework guarantees operational continuity, critical for AI workloads that demand 24/7 uptime.

This project exemplifies our ability to blend rapid execution with meticulous engineering. Our team’s expertise in retrofitting legacy facilities for cutting-edge IT loads, combined with our proactive risk management and vendor network, made us the ideal partner for this high-stakes initiative. As the installation progresses, we remain committed to delivering a solution that not only meets but exceeds the needs of a fast-moving AI leader.

Once complete, this 15MW deployment will serve as a testament to what’s possible when agilitymeets precision.

Stay tuned for updates as we bring this transformative project across the finish line.