Today’s economy is largely digital, but you already knew that. Cloud computing, artificial intelligence, streaming services, social media networks, and many more of our favorite platforms require large amounts of energy. That’s where data centers come in. It is estimated that the U.S. is home to 4,000+, and as demands continue to grow, the infrastructure is expected to grow exponentially.
As data center footprints expand, so does the need for robust, energy-efficient data center HVAC systems that can operate around the clock to keep the energy giants cooled down without fail.
In this blog, we’ll explore how precision sheet metal bending for HVAC helps leading manufacturers and OEMs meet the evolving standards of modern cooling systems. From understanding the role of data center CRAH and CRAC units to selecting the right forming technology, we’ll demonstrate how builders are utilizing advanced machinery to enhance performance, lower costs, and scale with confidence.
Why Data Center HVAC Systems Are Critical to Performance
For most modern data centers, HVAC cooling accounts for approximately 40% of total energy consumption. In other words, nearly half. A major reason for this is the rise of AI and hyperscale computing, which require massive amounts of energy to run efficiently.
When it comes to custom HVAC enclosures, two systems primarily dominate the space: CRAC (Computer Room Air Conditioning) and CRAH (Computer Room Air Handling). While each serves a different mechanical function, both require enclosures and airflow components built with tight tolerances, rugged materials, and efficient geometry. Any compromise in these areas can result in airflow imbalances, energy waste, or even premature failure, all of which can be costly for operators to handle.
For OEMs and manufacturers tasked with bringing these data center HVAC systems to life, today’s industry requires accuracy, repeatability, and scalability. This is where precision sheet metal bending for HVAC becomes all the more important to ensure HVAC components meet performance specs for today’s data-intensive environments.
The Difference Between CRAC and CRAH Systems
When analyzing the differences between CRAC vs. CRAH cooling units, it mainly comes down to the size of your data center. These units are the two dominant solutions for keeping servers at optimal operating temperatures, but they operate in unique ways.
CRAC (Computer Room Air Conditioner): For Self-Contained Cooling:
CRAC data center units function similarly to a traditional AC unit. These are designed for data center HVAC systems that use compressors and refrigerant to cool air, then circulate it back through the facility. These are standalone systems that are often favored in smaller facilities or legacy environments where chilled water is not readily available.
CRAH (Computer Room Air Handler): For Power From Chilled Water:
CRAH data center units, by contrast, use chilled water coils supplied by external chiller plants. These systems are more common in modern or hyperscale data centers because they offer greater efficiency, scalability, and control over large thermal loads. Simply put, if you’re building a data center HVAC system to handle AI, you’ll likely look into a CRAH unit.
The Role of Precision Sheet Metal Bending for HVAC
Whether you’re supplying enclosures for a compact CRAC unit or a modular CRAH system, form and function go hand in hand. Your sheet metal bending for HVAC units must be efficient and accurate. Custom HVAC enclosures control airflow, ensure insulation, and provide service access points that must perform under constant thermal and operational stress.
Without a precise sheet metal bending process for your HVAC units, you risk compromised uptime and customer satisfaction. Every panel, flange, and interface must be formed to tight tolerances to ensure the system performs efficiently and consistently. Poorly formed components can lead to air leakage, misalignment during assembly, and costly rework.
The HVAC components that rely on precise forming include:
- Access panels, service doors, and cabinets for proper sealing.
- Flanges and brackets to hold up to vibration and load.
- Duct connections for proper airflow control and low-pressure loss.
- Chassis frames for structural integrity.
Because data center environments demand continuous, scalable production, these enclosures must be fabricated with repeatability in mind. That’s why traditional press brakes, which may require more manual setup and handling, often fall short.
That’s why RAS metal folding machines are trusted by leaders across the HVAC and data center industries. Our precision-engineered fabrication machines, such as the XLTbend and Multibend-Center, offer many benefits for HVAC unit production.
- Bends are made with less operator intervention, improving ergonomics and safety.
- Material stays flat on the backgauge, reducing scratches and improving visual finish.
- Complex profiles with multiple bends can be formed faster and more accurately.
- Fewer setup changes lead to more uptime on the shop floor.
This level of precision and efficiency is especially valuable when manufacturing custom HVAC enclosures for CRAH or CRAC systems, where every bend must contribute to the overall performance of the cooling unit.
To learn more about our solutions, request a demo today. Our team will help you find the right folding machine to meet your data center’s HVAC needs.
FAQs
What role does metal bending play in data center HVAC systems?
Metal bending shapes the panels, ducts, and enclosures that house data center HVAC components. Precision bending ensures proper airflow control, structural integrity, and airtight seals critical for efficient, reliable cooling.
How does precision sheet metal impact HVAC efficiency in data centers?
Precision sheet metal bending for HVAC is critical. It reduces air leakage, improves thermal insulation, and ensures tight, consistent fits, leading to better airflow management, lower energy use, and higher project uptime.
What metals are commonly used for data center HVAC enclosures?
Custom HVAC enclosures often include galvanized steel, aluminum, and stainless steel. These materials offer strength, corrosion resistance, and thermal performance ideal for HVAC applications in high-demand environments.
What is a CRAC unit in a data center?
A CRAC (Computer Room Air Conditioning) unit cools air using refrigerant and an internal compressor. It’s a self-contained HVAC system that helps maintain optimal temperatures for smaller data centers.
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