Case Study

Live Datacentre Expansion — 48V DC Infrastructure Upgrade

A fibre infrastructure provider required expansion of an existing HAC-configured test lab facility with an additional 5 racks, upgraded AC & DC distribution, and enhanced earthing — all delivered within a live operational datacentre environment.

+5 New IT racks installed
48V DC New critical power distribution
Zero Operational downtime

Project Overview

Client: Fibre infrastructure provider (anonymous)
Location: England
Industry: Telecoms & Fibre Broadband
Objective: Upgrade the facility with additional IT racks and AC & DC power to match the existing HAC system.

Background & Challenge

The existing HAC-format 10-rack IT system required scalable expansion to support future telecoms infrastructure. Delivering this within a live datacentre meant engineering around restricted access, limited floor space, and strict safety and operational controls — while protecting critical services and maintaining resilience throughout.

Constraint: All works were completed in a live datacentre with restricted access, limited space, and multiple safety features — requiring disciplined sequencing and change control.

Solution Delivered

Dual A & B rectifier systems upgraded with an additional 10 x 63A outgoing circuits per system.
High-level containment extended for power and fibre distribution.
Five new compatible racks positioned and secured.
New 48V DC circuits installed to A1/A2 – B1/B2 rack-mounted PDUs.
Underfloor 1P 32A AC sockets installed.
Clean earth bar extended using a manufactured solution with disconnect link for future testing.

Engineering Approach

Works sequenced via the client change management process to reduce operational risk.
Off-site preparation completed to compress on-site installation time and reduce disruption.
Mechanical aids used for safe rack movement in a restricted environment.
All cabling installed to BS 7671:2018 A3:2024 with full NICEIC certification.
Functional switching and DC testing completed across all new circuits and PDUs.

Installation Methodology

Multi-party site survey completed to remove unknowns and confirm constraints.
Floor load-bearing verification and environmental checks (temperature, humidity, active cooling) performed.
Containment and routing planned in detail, including roof fixings and underfloor distribution.
RAMS, drawings and briefings completed in advance; access and PTW coordinated with the client.
Containment installed prior to rack delivery; DC and earth cabling pre-routed ready for timed terminations.
Racks transported flat-packed, rebuilt on-site, positioned to drawings; packaging removed and disposed of responsibly.
Rectifier works delivered one system per day to maintain resilience and reduce operational risk.
Testing and commissioning completed, including NICEIC certification, PDU functional checks, and DC test certificates.

Results & Benefits

Increased capacity for telecom critical loads and future expansion.
Zero downtime during installation and commissioning.
Documented materials, layouts and certification produced for future O&M needs.

Lessons Learned

Clear coordination with facilities and IT teams improves efficiency and reduces risk.
Detailed site surveys with materials lists improve timelines and labour efficiency.
Independent delivery supports coordination with existing equipment, maintenance, and future spares strategy.

Conclusion

The planned installation of additional IT racks and 48V DC power distribution enabled capacity growth without operational disruption. The project reinforces the value of rigorous planning, standards-compliant delivery and disciplined change control when upgrading mission-critical power environments.