The explosive growth of generative AI, machine learning, and high-performance computing (HPC) workloads has significantly increased the power demands of modern data centres. These applications rely heavily on GPU-accelerated servers that consume far more power than traditional CPU-based systems.

From medium-voltage (MV) grid connections to low-voltage (LV) rack distribution and monitoring, the architecture that delivers electricity inside data centres is under pressure. Rack densities are rising, equipment lead times are growing, and grid access is becoming a strategic constraint. Historically, typical enterprise data centre racks consumed between 5 and 15 kW of power. Today, AI-optimized racks frequently require 40–60 kW, and some advanced training clusters are pushing beyond 100 kW per rack.

The trajectory is still accelerating, with industry projections suggesting that average rack density will rise from roughly 36 kW in 2023 to around 50 kW by 2027 as AI adoption grows. Meanwhile, leading hyperscale deployments are already building infrastructure capable of supporting 100–200 kW per rack, with future designs targeting even higher densities.

According to GlobalData, data center electricity consumption is set to reach 945 terawatt-hours by 2030, roughly 3% of global consumption. By that point, in the US, where data centre growth is most expansive, they are expected to use more power than all other energy-intensive industries combined, including aluminium, steel, cement and chemicals.

Rising density reshapes internal power architecture

One of the most significant constraints on AI infrastructure deployment is access to sufficient electrical capacity, with many regions experiencing delays of several years in securing grid connections for large data centre projects.

This dynamic is forcing developers to rethink traditional assumptions about site selection. Historically, data centres prioritized connectivity, land availability, and latency considerations. Today, grid capacity is often the first gating factor in determining where facilities can be built. Developers are instead focusing on regions with large-scale renewable generation, hydropower, or proximity to major transmission infrastructure.

However, even when sufficient grid power is available, distributing it efficiently within the data centre presents new engineering challenges. Traditional data centre designs were built around relatively low-density server deployments, but as AI workloads increase rack power consumption by an order of magnitude, power distribution infrastructure must evolve accordingly.

What are the key pain points for data center developers?

Medium-voltage infrastructure

Utility power typically enters a data centre at medium voltage (between 13.8 kV and 34.5 kV) before being stepped down by transformers. AI-driven facilities require significantly larger incoming capacity and more robust substation designs.

Transformers

Higher site loads require larger or more numerous transformers to step power down from MV to usable LV distribution levels. These units must be engineered to meet high-efficiency and redundancy requirements while accommodating dynamic load profiles driven by AI workloads.

Switchgear

Switchgear systems are responsible for controlling and protecting electrical circuits within the facility. As load levels rise, high-capacity switchgear becomes essential for maintaining operational reliability and quickly isolating faults.

Busway and distribution

Power must then be delivered throughout the facility using busway systems or cable-based distribution networks. For high-density AI clusters, busway designs must support substantially higher current loads while maintaining flexibility for evolving rack configurations.

Rack power distribution units (PDUs)

At the rack level, PDUs deliver power directly to servers and networking equipment. In high-density deployments, these systems must accommodate much greater electrical loads while providing granular monitoring and circuit protection.

Monitoring and control

Power visibility is becoming essential as load patterns become more volatile. Advanced monitoring allows operators to track real-time electrical usage, identify inefficiencies, and detect potential faults before they escalate.

Carroll Technologies Group: transferring industrial expertise to digital infrastructure

Carroll Technologies Group has more than four decades of experience supplying electrical, communications, and safety equipment to demanding industrial environments. The company supports industries including mining, tunnelling, steel, oil and gas, renewable energy, and construction, providing equipment distribution, engineering expertise, and field service support.

Across these sectors, reliable power distribution is essential for maintaining operational continuity. Carroll Technologies supplies and services a wide range of electrical equipment for delivering and managing power in challenging conditions. This includes a broad portfolio of power distribution equipment designed to ensure reliable electrical performance in mission-critical operations, such as motor controls, voltage-monitoring equipment, and other electrical systems that manage and distribute power safely and efficiently.

Carroll Technologies works with leading electrical equipment manufacturers that provide many of the core components used in high-capacity power systems. Companies such as ABB, Eaton and Benshaw supply critical infrastructure, including medium and low-voltage switchgear, circuit protection systems, transformers, and power monitoring technologies. These components form the backbone of modern electrical distribution architectures, enabling facilities to manage high loads while maintaining safety and operational reliability.

In addition to large-scale electrical equipment providers, Carroll Technologies also works with specialized manufacturers focused on rugged power distribution systems designed for demanding industrial environments. Partners such as SMC Electrical Products and Line Power develop electrical power centres, substations, and control systems engineered for high-load applications. These modular distribution systems are increasingly relevant as data centre developers build larger, more power-dense facilities.

For cable management at data centers, CAB® Products specializes in rugged support systems and cable management designed for demanding industrial environments, including rings, saddles, clips, and a wide range of coated steel hooks and hangers that are used to organize, secure, and protect power and communication cables.

Beyond equipment supply, Carroll Technologies also provides service and repair capabilities for electrical systems from major manufacturers. As a factory-authorized repair center for multiple equipment providers, the company offers maintenance, troubleshooting, and refurbishment services that help operators maintain reliability and extend equipment lifecycles.

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