Inside the Infrastructure: Why Fusible Piping Systems Are Critical to Data Center Utility Construction

Fueled by the generative AI race with companies like OpenAI, xAI, and Meta investing billions in next-generation compute campuses, data center construction has entered a new era.

But while headlines highlight GPU stacks and megawatt power draws, the more pressing challenge lies just beyond the racks: the design, installation, and long-term performance of the utility infrastructure that drives these massive facilities. When you're delivering a 100 MW hyperscale site with five 9s uptime, a single failed joint in a chilled water return loop isn’t just a maintenance hiccup, it’s a critical risk.

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The Surge Underway

By the end of 2024, U.S. primary data center markets had over 6,350 MW under construction, more than double the 3,077.8 MW reported just a year earlier (CBRE). And with the market projected to grow from $67 billion in 2025 to $133 billion by 2032, developers and contractors alike are racing to meet demand (Persistence Market Research).

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Managing Massive Water Use

Despite their digital nature, modern data centers consume enormous amounts of water, particularly those supporting AI workloads and high-density compute clusters. A single 100 MW facility can use up to 2 million liters of water per day, equivalent to the daily consumption of roughly 6,500 households. This demand is driven primarily by cooling systems, where water is used in evaporative processes, chilled water loops, or liquid-cooled hardware.

The industry’s average water usage effectiveness (WUE) is around 1.8 liters per kilowatt-hour, though best-in-class campuses are now pushing below 0.5 L/kWh through closed-loop and hybrid cooling designs (Tech Targets). But even with efficiency gains, the location of these campuses creates tension: as of early 2025, nearly 40% of U.S. data centers are located in regions facing high to extreme water stress. This reality is prompting developers, engineers, and municipalities to rethink how utility systems are designed, constructed, and maintained with long-term reliability and minimal leakage more important than ever.

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Utility Systems Built for Scale and Scrutiny

These buried systems are not your typical mechanical job. We're talking about:

• Chilled water loops, often 8–24" HDPE, operating at 100+ psi
• Full-loop firewater systems needing UL/FMVSS compliance and redundant paths
• Climate-sensitive stormwater/drainage built for one-in-100-year events
• Compact PP R hydronic systems running behind CRAH units or heat exchangers
• Coating thresholds in metal systems that are extremely reistant to corrosion

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Thermoplastics to the Rescue

HDPE (PE4710 / PE100)

High-density polyethylene is a common choice for buried chilled water and fire systems, thanks to its flexibility, corrosion resistance, and monolithic fused joints. Most contractors use DR11 or DR9 pipe, rated up to 200–250 psi, depending on design pressures. Compliant with AWWA C906 and NSF-14, HDPE performs exceptionally well in aggressive soils and seismic zones. It's rated for a 100-year lifespan under ISO 9080 and can accommodate deflection and minor movement without failure.

PP-R / PP-RCT

Polypropylene-random copolymer systems are ideal for indoor mechanical piping, especially closed-loop glycol systems and CRAH unit connections. PP-R is scale-resistant and inert, with continuous service ratings up to 180°F. PP-RCT, a higher-crystallinity variant, allows for even greater pressure performance and is becoming more common in rooftop or riser-based installations where space is tight but temperature demands are high.

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On-Site Realities for Contractors

• Laydown space is tight, schedules are aggressive, and delays aren’t affordable
• Fusion methodologies require DataLogger® traceability, operator logs, and heat numbers — sometimes GPS-tagged
• Fusion equipment needs on-site servicing, not shipping back to the factory
• Buildouts are often phased, requiring repeatability and consistency across segments

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Built for Longevity, Not Just Commissioning

Increasingly, owners are tightening material standards to reduce long-term risk. Firewater systems now commonly require compliance with UL 651, FM 1613, or AWWA C906. Coated components such as valves or steel risers are often specified with fusion-bonded epoxy (FBE) or polyurethane systems that meet AWWA C213 or C222. Where water quality is critical, NSF-14 and NSF-61 certification may be required. For projects involving fusion, ISO 12176-2 often governs joint traceability, requiring data logging and, in some cases, GPS-tagged weld records.

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Built for Scale. Backed by Field Expertise.

Milford doesn’t just ship products, we support the infrastructure backbone. Our team stands in the trenches and helps keep builds moving on 24/7 timelines by providing:

• Fusible pipe, fitting, valve, and restraint packages
• Prefab support where access is limited
• Anti-corrosion coating solutions for critical, corrosion-prone metallic components
• Hands-on crew enablement, not just product delivery
• McElroy fusion equipment (TracStar® iSeries, Tritan™ 560, Spider™ 125, and more)
• DataLogger® QA tracking to satisfy owner and auditor demands (McElroy)
• Mobile service teams and operator training, delivering uptime and installation confidence

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